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
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• 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
MPGGalsAC kWh(mi)(N)(hr)(10 mi)(10 mi)(mi)GasolineElectricityTotalRepsChargeHighwayUrbanCycle
Each total distance slightly greater than 600 miles. HEV version = 27 mpg
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
MPGGalsAC kWh(mi)(N)(hr)(10 mi)(10 mi)(mi)GasolineElectricityTotalRepsChargeHighwayUrbanCycle
Each total distance slightly greater than 600 miles. HEV version = 27 mpg
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
Data from 150 Hymotion Prius with V2Green and Kvaser loggers
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
Data from 150 Hymotion Prius with V2Green and Kvaser loggers
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
Data from 150 Hymotion Prius with V2Green and Kvaser loggers
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
Data from 150 Hymotion Prius with V2Green and Kvaser loggers
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
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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
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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