U.S. Department of Energy’s Vehicle Technologies Program€¦ · Virginia Clean Cities and Hampton Roads Clean Cities Coalition - Virginia Electric Drive Road Show Poquoson, VA

U.S. Department of Energy’s Vehicle Technologies Program -

Virginia EV Road Show - PHEV Operations and Performance

Jim Francfort

Virginia Clean Cities and Hampton Roads Clean Cities Coalition - Virginia Electric Drive Road ShowPoquoson, VA – August 2009This presentation does not contain any proprietary or sensitive information

2

AVTA Background and Goals• The Advanced Vehicle Testing Activity (AVTA) is part of

DOE’s Vehicle Technologies Program• The Idaho National Laboratory (INL) and Electric

Transportation Engineering Corporation (ETEC) conduct the AVTA. Argonne National Laboratory performs dynamometer testing

• The AVTA goals: – Provide benchmark data to technology modelers,

research and development programs, vehicle manufacturers (via VSATT), and target and goal setters

– Assist fleet managers in making informed early adaptor vehicle purchase, deployment and operating decisions

3

AVTA Testing by Technology • Plug-in hybrid electric vehicles (PHEV)

– 12 models, 188 vehicles, 800,000 fleet test miles• Hybrid electric vehicles (HEV)

– 17 models, 45 vehicles, 4.5 million test miles• Neighborhood electric vehicles

– 23 models, 200,000 test miles • Hydrogen ICE (internal combustion engine) vehicles

– 7 models, 400,000 test miles• Full-size battery electric vehicles (BEVs)

– 40 EV models, 5+ million test miles• Urban electric vehicles

– 3 models, 1 million test miles

4

12 PHEVs Models in Testing/Demonstrations • Hymotion Prius (A123Systems)• Hymotion Escape (A123Systems)• Ford E85 Escape (Johnson Controls/Saft)• EnergyCS Prius, 2 models (Valance and Altair Nano)• Electrovaya Escape (Electrovaya)• Hybrids Plus Escape, 2 models (Hybrids Plus and K2

Energy Solutions)• Hybrids Plus Prius (Hybrids Plus)• Manzanita Prius (lead acid)• Manzanita Prius (Thunder Sky)• Renault Kangoo (Saft NiCad)• (All batteries are Lithium unless noted)

5

PHEV Testing Methods and Objectives• Perform independent testing of PHEVs, using:

– Baseline performance testing: closed test tracks and dynamometers

– Accelerated testing: dedicated drivers operating on defined onroad loops

– Fleet testing: everyday unstructured \ non-directed fleet and public use, with onboard data loggers

– Laboratory testing of PHEV batteries• Testing used to document:

– Battery life, charging patterns and profiles– Vehicle operations, fuel use (electricity and gasoline)

and infrastructure requirements – Driver influences on fuel use– Individual PHEV models and PHEV concepts– PHEV life-cycle costs

6

PHEV Operating Modes • Charge sustaining (CS) mode: from start to finish of a

single trip, there is no energy available for electric drive propulsion in the PHEV battery. Therefore, the battery state-of-charge (SOC) is sustained

• Charge depleting (CD) mode – from start to finish of a single trip, there is energy available for partial or full electric drive propulsion in the PHEV battery. Therefore, the battery SOC is being depleted during the trip

• Mixed CD/CS mode – there is energy in the battery pack at the start of a single trip, but the PHEV battery is fully depleted before the trip ends

7

• 5 kWh A123Systems (Li) and Prius packs (AC kWh)Hymotion Prius Gen I – UDDS Fuel Use

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

8

Hymotion Prius Gen I – HWFEDS Fuel Use• 5 kWh A123Systems (Li) and Prius packs (AC kWh)

Hymotion PHEV Prius MPG & kWh - HWFEDS 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

9

PHEV Accelerated Testing• Accelerated testing in Phoenix over 5,440 onroad 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

10

Hymotion Prius Gen I – Accelerated Testing

101.1 6.0584.1060015120440

127.24.81

79.5 Weighted Average5,440167140431002340Total54.811.0215.060031218220073.28.4335.986006128210058.311.3643.99640812628068.98.9855.336001012426073.18.5479.8260015124040

106.95.7887.2260015122240

115.9 5.37122.026003081120136.336006040110

MPGGalsAC kWh(mi)(N)(hr)(10 mi)(10 mi)(mi)GasolineElectricityTotalRepsChargeHighwayUrbanCycle

Each total distance slightly greater than 600 and 640 miles. HEV version = 44 mpg

11

Hymotion Prius Gen II – Accelerated Testing

57.7

56.5

61.8

58.8

70.8

103.3

90.6

99.8

64.3

84.2

62.1

80.1

117.6

MPG

7,840600

600

640

600

600

600

600

600

600

600

600

600

600

(mi)

Total

16.01

26.48

41.38

33.38

63.46

75.18

70.98

75.14

64.36

44.97

71.28

124.50

111.43

AC kWh

Electricity

Weighted Average10.41

10.91

10.71

10.54

8.88

6.10

6.83

6.20

9.70

7.2

9.8

8.105

5.205

Gals

Gasoline

92.4

100.0

98.9

101.7

65.5

135.6

64.2

Recalculated without incomplete

charges

15124040

15120440

15120440

15122240

15122240

167140431002340Total312182200

61282100

8126280

10124260

15124040

15122240

3081120

6040110

(N)(hr)(10 mi)(10 mi)(mi)

RepsChargeHighwayUrbanCycle

Each total distance slightly greater than 600 and 640 miles. HEV version = 44 mpg

12

• 40 mile city/highway loops – high ambient temperatures results in incomplete charging

Hymotion Prius Gen II – Accelerated Testing

ETEC Hymotion Prius: 40 mi City/Hwy Loops

40

50

60

70

80

90

100

110

120

130

140

150

160

40 50 60 70 80 90 100 110 120 130 140 150 160Max Battery Inlet Air Temperature [degF]

Max

Bat

tery

Cel

l Tem

pera

ture

[deg

F] .

Complete Charge Max Bat t Cell Temperature [degF]

Incomplete Charge Max Batt Cell Temperature [degF]

13

Energy CS Prius (Valance Bat.) Acc. Testing

42.714.2925.0060015120440

128.14.78115.586006040110

66.1 Weighted Average544014798425002340Total57.810.4612.9860031218220070.88.8122.676006128210065.810.0939.046408126280

103.75.9065.006001012426055.511.3632.44600512404056.111.0531.526005122240

77.9 7.95 86.216003081120

MPGGalskWh(mi)(N)(hr)(10 mi)(10 mi)(mi)

GasolineElectricityTotalRepsChargeHighwayUrbanCycle

Each total distance slightly greater than 600 miles. HEV version = 44 mpg

14

* 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

359.60

AC kWh

Electricity

05.62005120440

0

3,04012387614801560Total60031218220060061282100

38.616.614.4640812628045.113.310.460010124260

07.0200512404006.02005122240

04.66003081120

1.76006040110

MPGGalsMi/kWh(mi)(N)(hr)(10 mi)(10 mi)(mi)

GasolineTotalRepsChargeHighwayUrbanCycle

15

Hymotion Escape – Accelerated Testing

38.715.99

45.3

41.114.9157.5160015120440

53.111.52

42.5 Weighted Average5440162134431002340Total33.517.7226.0960031218220039.815.6958.646006128210041.316.0577.696408126280

13.7097.186001012426051.511.92114.1460015124040

76.2960015122240

45.713.51163.296003081120198.936006040110



16

Electrovaya Escape – Accelerated Testing

43.1

65.1

37.316.4271.360015120440

9.55

36.7Weighted Average5440162134431002340Total30.919.0113.3160031218220029.221.1720.856006128210040.816.3042.72640812628037.316.6444.796001012426029.820.7355.8460015124040

14.3469.860015122240

34.717.54101.136003081120135.246006040110



17

PHEV Fleet Testing Partners• 75+ testing partners in the U.S. and Canada:

– 36 Electric utilities and 2 clean-air agencies – 10 City, county and state governments– 7 Private companies and advocacy organizations– 8 Universities and colleges and 4 Canadian provinces– 2 PHEV companies 1 sea port and 1 DOD facility

• Testing partners include:– A123Systems, EnergyCS, NYSERDA, NRECA, UC

Davis, Fairfax County, Google.org, Austin Energy, Central Vt PSC, Duke Energy, Advanced Energy, Progress Energy, SDGE, Basin Electric, Buckeye Power, WI Public Power Inc., Madison GE, SCANA Corp., HCATT, BC Hydro, BC Government, various Washington State groups

18

PHEVs and Demonstration Locations

30+18 - Canada

8

341

12

141 3

2

6

5

44+6

3

1

1+1

10+15

1

4

3

111

228 Total177 Operating41 Coming in ‘0910 Out of Service

1

1 in DC

19

PHEV Fleet Testing Reports• Summary reports posted monthly on web • Individual vehicle reports only go to the respective fleets

each month, 950+ reports to date (July 1, 2009)• 150 Hymotion Prius PHEVs, 710,000 miles, 76,000 trips,

18,000 charging events, 43,000 kWh used. V2Green and Kvaser data logger reports

20

Hymotion Prius (V2Green Logger) Fleet Tests• March 01/08 to July 01/09. 110 PHEVs, 498,000 miles,

54,000 trips, 12,400 charging events and 31,000 kWh used

21

• MPG and aggressive driving impacts March ‘08 – May ‘09

Hymotion Prius PHEVs – CS Trips

MPG & Driver Aggressiveness for 17,300 CS Trips, 275,000 miles (15.9 miles average trip distance)

0

10

20

30

40

50

60

70

80

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250

MPG

Driver Aggressiven

ess

Data from 150 Hymotion Prius with V2Green and Kvaser loggers

22

• MPG and aggressive driving impacts March ‘08 – May ‘09

Hymotion Prius PHEVs – CS/CD Mixed Trips

MPG & Driver Aggressiveness for 5,900 CD/CS Trips, 149,000 miles (25.3 miles average trip distance)

0

10

20

30

40

50

60

70

80

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250

MPG

Driver Aggressiven

ess


23

Hymotion Prius PHEVs – CD Trips• MPG and aggressive driving impacts March ‘08 – May ‘09

MPG & Driver Aggressiveness for 22,700 CD Trips, 151,000 miles (6.7 miles average trip distance)

0

10

20

30

40

50

60

70

80

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250

MPG

Driven Aggressiven

ess


24

MPG Results - Charge Depleting (CD) Mode

Percent of 22,700 CD Trips and 151,000 CD Miles by MPG Grouping

0%

5%

10%

15%

20%

25%

30%

35%

40%

<40 MPG 40 to <60 MPG 60 to <80 MPG 80 to< 100 mpg 100 to <150 MPG >=150 MPG

Percentage CD Trips by MPG Group

Percentage CD Miles by MPG Group


25

Fleet Testing Results – Monthly Trends

Percent Monthly Trips Driven by Operating Mode

5%

15%

25%

35%

45%

55%

65%

75%

85%

April08

M ay08

June08

July 08 Aug 08 Sept08

Oct 08 Nov08

Dec 08 Jan 09 Feb 09 M ar 09 April09

M ay09

June"09

% CD Trips % CD/CS Trips % CS Trips

Data from 110 Hymotion Prius with V2Green loggers

Percent Monthly Miles Driven by Operating Mode

15%

20%

25%

30%

35%

40%

45%

50%

55%

April08

May08

June08

July 08 Aug08

Sept08

Oct 08 Nov08

Dec08

Jan 09 Feb 09 Mar09

April09

May09

June"09

% CD M iles % CD/CS M iles % CS M iles

Monthly MPG by Operating Mode

40

45

50

55

60

65

70

75

80

April08

May08

June08

July 08 Aug08

Sept08

Oct 08 Nov08

Dec08

Jan 09 Feb 09 Mar09

April09

May09

June"09

Mile

s pe

r Gal

lon

(MPG

)

M PG - A ll M PG CD M PG CD/CS M PG CS

26

Hymotion Prius PHEV MPG by Temperature


Hymotion Prius Fleet Fuel Economy

0

10

20

30

40

50

60

70

80

<-20C -20C to -10C -10C to 0C 0C to 10C 10C to 20C 20C to 30C 30C to 40C >40C

Average Ambient Temperature [C]

Ave

rage

Fue

l Eco

nom

y [M

PG

]

All Trips

CD

CD/CS

CS

27

EnergyCS Prius (Valance Battery) Fleet Tests

42%

9%

48%

Percent of Trips

Percent Total Distance

Miles Driven

Number of Trips

Fuel Economy (mpg)

Trip Type

24%3,91195378.1CD

829

184

1,966

7,933

4,896

16,470

44.4

56.1

53.0

48%CS

30%CD/CS

All

MPG By Vehicle and Operating Mode

0102030405060708090

100

All Trips CD CD/CS CS

Mile

s pe

r Gal

lon

(Gas

olin

e)Vehicle A Vehicle B Vehicle C Vehicle D Vehicle E

Total Miles Driven by Vehicle

0500

1,0001,5002,0002,5003,0003,5004,0004,5005,0005,5006,0006,5007,000

Vehicle A Vehicle B Vehicle C Vehicle D Vehicle E

Num

ber o

f Trip

s

28

EnergyCS Prius (Altairnano Bat.) Fleet Tests

37%

11%

52%

Percent of Trips

Percent Total Distance

Miles Driven

Number of Trips

Fuel Economy (mpg)

Trip Type

24%1,72447573CD

339

101

915

2,431

3,156

7,312

47

68

60

33%CS

43%CD/CS

All

4.2Average number of trips between charging event

33.7Average distance between charging event (miles)

1.2Average number of charging events per vehicle, per day, when driven

17.7Average number of charging events per vehicle per month when driven

2.0Average energy per charging event (DC kWh)

21.9Average charging event duration (hours)

590Total charging energy (AC kWh)

217Total number of charging events

29

PHEV Charging Infrastructure Cost Report • Analyzes PHEV infrastructure requirements in single and

multi-family residential, and commercial facilities as well as driving trends. No site specific costs

• Charging infrastructure equipment/administrative costs:– Levels 1 (120V, 15 or 20 amp) and 2 residential– Levels 1 and 2 (208/240V ~40 amp) apartment complex– Level 2 commercial facility

• Battery sizes & charge times for various PHEV platforms• Power electronics & battery costs for PHEV platforms

$878$94$424$360Total Level 1 Cost

$112$9$43$60Administration costs

$516$85$131$300Residential circuit installation (20A branch

circuit, 120 VAC/1-Phase)

$250- -$250- -EVSE (charge cord)

TotalPermitsMaterialLaborLevel 1 Residential

Report @ http://avt.inl.gov/pdf/phev/phevInfrastructureReport08.pdf

30

PHEV Advantages• Reduced petroleum consumption and emissions• Optimized fuel efficiency and performance• Recover energy during regenerative braking• Use existing gas station infrastructure • Minimal electric grid changes needed - add connector

and electric vehicle supply equipment (EVSE)• At home battery charging, well below cost of gasoline• Zero emission potential (local) • Lower fuel costs compared to HEVs• Energy security by displacing imported petroleum with

domestically generated electricity• Potential for off-peak charging• V2Grid (big maybe)

Primary Source Electric Drive Transportation Association (EDTA)http://www.electricdrive.org/index.php?ht=d/Articles/cat_id/5599/pid/9673

31

PHEV Challenges • Cost and complexity of two powertrains• Drivers adapting to dual-fueling scenario• Component availability - batteries, powertrains, power

electronics (early challenge)• Higher initial capital cost• Cost of batteries and potential battery replacements• Added weight• Probable need for public recharging infrastructure• Challenge to move charging to off-peak times • If large PHEV batteries are successful, will BEVs replace

PHEVs?

Primary source EDTAhttp://www.electricdrive.org/index.php?ht=d/Articles/cat_id/5599/pid/9673

32

Announced PHEV Introductions*• 2009 Fisker Karma S Plug-in Hybrid (maybe 2010)• 2010 Saturn VUE Plug-in Hybrid • 2010 Toyota Plug-in Hybrid (?)• 2010 Chevrolet Volt Extended Range BEV• 2010 Kia LPG and Electric “hybrid”• 2009 Chery (China, Berkshire Hathaway) BYD PHEV in

Europe• 2011 BYD F3DM Plug-in Hybrid • 2012 Ford Escape Plug-in Hybrid• 2012 Hyundia PHEV• ? AFS Trinity SUV• * Presenter makes no accuracy claim for the above dates

and products. Some info based on media reportsPrimary source: EDTA http://www.electricdrive.org/index.php?ht=d/sp/i/11551/pid/11551

33

Announced BEV Introductions*• 2009 Subaru 4 seat Stella or R1e (2 in New York now)• 2009 Chrysler EVs (showing concepts)• 2009 Smart for Two EV• 2009 ZENN city BEV • 2009 Chery (China, Berkshire Hathaway) BYD EV in China• 2009 Tesla / Daimler Smart Car BEV• 2010 BMW electric Mini (maybe 2009)• 2010 Chrysler EV• 2010 Miles EV• 2010 Mitsubishi \ Peugeot iMiEV BEV• * Presenter makes no accuracy claim for the above dates

and products. Some info based on media reports

Primary source: EDTA http://www.electricdrive.org/index.php?ht=d/sp/i/11551/pid/11551

34

Announced BEV Introductions* – cont’d• 2010 Nissan BEV • 2010 Ford Battery Electric Van• 2011 Tesla Model S sedan• 2011 BYD e6 Electric Vehicle • 2011 Ford Battery Electric Sedan • 2011 Opel Ampera Extended Range BEV (Europe)• 2012 Toyota EV sedan• ? Volkswagen and Toshibia EV develop letter of intent• * Presenter makes no accuracy claim for the above dates

and products. Some info based on media reports

Primary source: EDTAhttp://www.electricdrive.org/index.php?ht=d/sp/i/11551/pid/11551

35

AVTA Webpage Use and Gasoline CostsINL WWW Visitors & Gasoline Costs (all formulations, areas, and grades)

2,500

5,000

7,500

10,000

12,500

15,000

17,500

20,000

22,500

25,000

27,500

30,000

32,500

35,000

37,500

40,000

May

'02

June

July

Aug

Sept

Oct

Nov

Dec

'02

Jan

'03

Feb

Mar

chAp

rilM

ay

June

July

Aug

Sept

Oct

Nov

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

April

May

June

July

Aug

Sept

Oct

Nov

Dec

'08

Jan

'09

Feb

Mar

chAp

rilM

ayJu

neJu

ly

Num

ber o

f Mon

thly

Vis

itors

$1.25

$1.50

$1.75

$2.00

$2.25

$2.50

$2.75

$3.00

$3.25

$3.50

$3.75

$4.00

$4.25

All G

rade

s G

asol

ine

Cos

ts -

End

of M

onth

Visitors (left axis)

Gasoline Cost (right axis)

Linear (Gasoline Cost (right axis) )

Linear (Visitors (left axis))

36

This work is supported by the U.S. Department of Energy’s Vehicle Technologies Program

http://avt.inl.gov or

http://www1.eere.energy.gov/vehiclesandfuels/avta/

Additional Information

INL/CON-09-16608

Acknowledgement

U.S. Department of Energy’s Vehicle Technologies Program€¦ · Virginia Clean Cities and Hampton Roads Clean Cities Coalition - Virginia Electric Drive Road Show Poquoson, VA

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