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Annual Progress Report for Advanced Vehicle Technology Analysis and Evaluation Activities

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Annual Progress Report for Advanced Vehicle Technology Analysis and Evaluation Activities ADVANCED VEHICLE TECHNOLOGY ANALYSIS AND EVALUATION ACTIVITIES Less dependence on foreign oil, and eventual transition to an emissions-free, petroleum-free vehicle FreedomCAR and Vehicle Technologies Program A Strong Energy Portfolio for a Strong America Energy efficiency and clean, renewable energy will mean a stronger economy, a cleaner environment, 2004 and greater energy independence for America. Working with a wide array of state, community, industry, and university partners, the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy ANNUAL invests in a diverse portfolio of energy technologies. PROGRESS For more information contact: EERE Information Center REPORT 1-877-EERE-INF (1-877-337-3463) www.eere.energy.gov Acknowledgement We would like to express our sincere appreciation to QSS Group, Inc., Oak Ridge National Laboratory, and Argonne National Laboratory for their technical and artistic contributions in preparing and publishing this report. In addition, we would like to thank all the participants for their contributions to the programs and all the authors who prepared the project abstracts that comprise this report. This document highlights work sponsored by agencies of the U.S. Government. Neither the U.S. Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the U.S. Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the U.S. Government or any agency thereof. Printed on recycled paper U.S. Department of Energy Office of FreedomCAR & Vehicle Technologies 1000 Independence Avenue, S.W. Washington, DC 20585-0121 FY 2004 Annual Progress Report for Advanced Vehicle Technology Analysis and Evaluation Activities Energy Efficiency and Renewable Energy Office of FreedomCAR and Vehicle Technologies Lee Slezak, Technology Manager Advanced Vehicle Technology Analysis and Evaluation Activities FY 2004 Annual Progress Report CONTENTS I. INTRODUCTION............................................................................................................................. 1 II. MODELING AND SIMULATION ................................................................................................. 7 A. Technical Targets Evaluation, Analysis, and Tool Enhancement National Renewable Energy Laboratory, A. Brooker................................................................ 7 B. Vehicle Systems Optimization, Application, and Distributed Computing National Renewable Energy Laboratory, T. Markel.................................................................. 9 C. Well-to-Wheel Analysis of Current Engine and Fuel Cell Vehicle Technologies Argonne National Laboratory, A. Rousseau.............................................................................. 12 D. Fuel Cell Vehicle Simulation and Control Argonne National Laboratory, A. Rousseau.............................................................................. 16 E. High-Fidelity Component Model Integration into PSAT Argonne National Laboratory, A. Rousseau.............................................................................. 19 F. Dual Source Energy Storage Potential for Fuel Cell Vehicle Applications Argonne National Laboratory, A. Rousseau.............................................................................. 22 G. Automotive System Cost Modeling Oak Ridge National Laboratory, S. Das .................................................................................... 26 H. Model Validation Procedure Improvements in PSAT Argonne National Laboratory, A. Rousseau.............................................................................. 29 I. PSAT and PSAT-PRO Maintenance Argonne National Laboratory, A. Rousseau.............................................................................. 32 III. INTEGRATION AND VALIDATION ........................................................................................... 35 A. Hydrogen ICE Hybrid Powertrain Configuration Development Argonne National Laboratory, M. Pasquier............................................................................... 35 B. Hydrogen ICE Hybrid Test Setup Instrumentation and Implementation Argonne National Laboratory, M. Pasquier............................................................................... 41 C. Mobile Automotive Technology Testbed (MATT) Functional Validation Argonne National Laboratory, M. Pasquier............................................................................... 48 IV. LABORATORY TESTING AND BENCHMARKING ................................................................ 51 A. MY04 Prius Benchmarking Argonne National Laboratory, M. Duoba.................................................................................. 51 iii Advanced Vehicle Technology Analysis and Evaluation Activities FY 2004 Annual Progress Report CONTENTS (CONT.) B. Hydrogen-Fueled Vehicles Argonne National Laboratory, H. Ng ........................................................................................ 55 C. HEV Test Methods and Procedure Analysis Argonne National Laboratory, M. Duoba.................................................................................. 59 V. OPERATIONAL AND FLEET TESTING .................................................................................... 62 A. Arizona Public Service (APS) Alternative Fuel (Hydrogen) Pilot Plant Monitoring, Hydrogen and Compressed Natural Gas (CNG) Dispenser Testing (real-time fuel blending), and Hydrogen Internal Combustion Engine (ICE) Vehicle Testing Idaho National Laboratory, J. Francfort, T. Murphy ................................................................. 62 B. Hybrid Electric Vehicles (HEVs) Testing Idaho National Laboratory, J. Francfort, T. Murphy ................................................................. 66 C. Testing of Neighborhood Electric Vehicles (NEVs) Idaho National Laboratory, J. Francfort, T. Murphy ................................................................. 71 D. Urban Electric Vehicles Testing Idaho National Laboratory, J. Francfort, T. Murphy ................................................................. 73 E. Oil Bypass Filter Testing Idaho National Laboratory, J. Francfort, T. Murphy ................................................................. 76 F. Advanced Technology Medium and Heavy Vehicles Testing National Renewable Energy Laboratory, L. Eudy..................................................................... 80 VI. LIGHT VEHICLE ANCILLARY SYSTEMS ............................................................................... 85 A. Light Vehicle Ancillary Load Reduction National Renewable Energy Laboratory, J. Rugh ..................................................................... 85 iv Advanced Vehicle Technology Analysis and Evaluation Activities FY 2004 Annual Progress Report I. INTRODUCTION On behalf of the U.S. Department of Energy’s Office of FreedomCAR and Vehicle Technologies (FCVT), I am pleased to submit the Annual Progress Report for fiscal year 2004 for the Advanced Vehicle Technology Analysis and Evaluation (AVTAE) team activities. In prior years, these activities were reported in the Light Vehicle Propulsion and Ancillary Subsystems annual report. Mission The AVTAE team’s mission is to evaluate the technologies and performance characteristics of advanced automotive powertrain components and subsystems in an integrated vehicle systems context. This work is directed towards evaluating and verifying the targets of the FCVT technology R&D teams and to provide guidance in establishing roadmaps for achievement of these goals. Objective The prime objective of the AVTAE team activities is to evaluate program targets and associated data that will enable the FCVT technology R&D teams to focus research on areas that will maximize the potential for fuel efficiency improvements and tailpipe emissions reduction. AVTAE accomplishes this objective through a tight union of computer modeling and simulation, integrated component testing and emulation, and laboratory and field testing of vehicles and systems. AVTAE also supports the FCVT Program goals of fuel consumption reduction by developing and evaluating enabling vehicle system technologies in the area of light vehicle ancillary loads reduction. The integration of computer modeling and simulation, hardware-in-the-loop testing, vehicle benchmarking, and fleet evaluations is critical to the success of the AVTAE team. Each respective area feeds important information back into the other, strengthening each aspect of the team. A graphical representation of this is shown in Figure 1 below. Figure 1. Integration of AVTAE computer modeling and testing activities. 1 Advanced Vehicle Technology Analysis and Evaluation Activities FY 2004 Annual Progress Report FY 2004 AVTAE Activities AVTAE provides an overarching vehicle systems perspective in support of the technology R&D activities of DOE’s FCVT and Hydrogen, Fuel Cells & Infrastructure Technologies (HFCIT) Programs. AVTAE uses analytical and empirical tools to model
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