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Advanced Components for Electric and Hybrid Electric Vehicles

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Advanced Components for Electric and Hybrid Electric Vehicles M m III Hi 1 MIST ^^^^^^1 jljlll 1 iV PUBLICATIONS A11104 EfifilfiT United States Department of Commerce Technology Administration National Institute of Standards and Technology NIST Special Publication 860 Advanced Components for Electric and Hybrid Electric Vehicles Workshop Proceedings October 27-28, 1993 Gaithersburg, Maryland K. L. Stricklett, Editor 7he National Institute of Standards and Technology was established in 1988 by Congress to "assist industry in the development of technology . needed to improve product quality, to modernize manufacturing processes, to ensure product reliability . and to facilitate rapid commercialization ... of products based on new scientific discoveries." NIST, originally founded as the National Bureau of Standards in 1901, works to strengthen U.S. industry's competitiveness; advance science and engineering; and improve public health, safety, and the environment. One of the agency's basic functions is to develop, maintain, and retain custody of the national standards of measurement, and provide the means and methods for comparing standards used in science, engineering, manufacturing, commerce, industry, and education with the standards adopted or recognized by the Federal Government. As an agency of the U.S. Commerce Department's Technology Administration, NIST conducts basic and applied research in the physical sciences and engineering and performs related services. The Institute does generic and precompetitive work on new and advanced technologies. NIST's research facilities are located at Gaithersburg, MD 20899, and at Boulder, CO 80303. Major technical operating units and their principal activities are listed below. For more information contact the Public Inquiries Desk, 301-975-3058. Technology Services Manufacturing Engineering Laboratory • Manufacturing Technology Centers Program • Precision Engineering • Standards Services • Automated Production Technology • Technology Commercialization • Robot Systems • Measurement Services • Factory Automation • Technology Evaluation and Assessment • Fabrication Technology • Information Services Materials Science and Engineering Electronics and Electrical Engineering Laboratory Laboratory • Intelligent Processing of Materials • Microelectronics • Ceramics • Law Enforcement Standards • Materials Reliability' • Electricity • Polymers • Semiconductor Electronics • Metallurgy • Electromagnetic Fields' • Reactor Radiation • Electromagnetic Technology' Building and Fire Research Laboratory Chemical Science and Technology • Structures Laboratory • Building Materials • Biotechnology • Building Environment • Chemical Engineering' • Fire Science and Engineering • Chemical Kinetics and Thermodynamics • Fire Measurement and Research • Inorganic Analytical Research • Organic Analytical Research Computer Systems Laboratory • Process Measurements • Information Systems Engineering • Surface and Microanalysis Science • Systems and Software Technology • Thermophysics^ • Computer Security • Systems and Network Architecture Physics Laboratory • Advanced Systems • Electron and Optical Physics • Atomic Physics Computing and Applied Mathematics • Molecular Physics Laboratory » Radiometric Physics • Applied and Computational Mathematics^ • Quantum Metrology • Statistical Engineering^ • Ionizing Radiation • Scientific Computing Environments^ • Time and Frequency' • Computer Services^ • Quantum Physics' • Computer Systems and Communications^ • Information Systems 'At Boulder, CO 80303. ^Some elements at Boulder, CO 80303. NIST Special Publication 860 Advanced Components for Electric and Hybrid Electric Vehicles Workshop Proceedings October 27-28, 1993 Gaithersburg, Maryland K. L. Stricklett, Editor Electricity Division Electronics and Electrical Engineerinag Laboratory National Institute of Standards and Technologay Gaithersburg, MD 20899 March 1994 U.S. Department of Commerce Ronald H. Brown, Secretary Technology Administration Mary L. Good, Under Secretary for Technology National Institute of Standards and Technology Arati Prabhakar, Director National Institute of Standards U.S. Government Printing Office For sale by the Superintendent and Technology Washington: 1994 of Documents Special Publication 860 U.S. Goverrmient Printing Office Natl. Inst. Stand. Technol. Washington, DC 20402 Spec. Publ. 860 212 pages (March 1994) CODEN: NSPUE2 Executive Summary This is a key period in the development of elec- vanced battery development, and the imperatives tric and hybrid electric vehicles. The landmark for commercial success of EVs and HEVs. The 1990 legislation in California requires that 2 per- working sessions were five parallel meetings on cent of new automobiles be Zero Emission Vehi- Energy Conversion Systems, Energy Storage Sys- cles (ZEV) in 1998, rising to 10 percent in the tems, Electric Propulsion Systems, Controls and year 2005. This can only be met by Electric Ve- Instrumentation, and Ancillary Systems. Each hicles (EV). The impact of this legislation could session chairman had been requested to develop lead to as many as 150,000 EV per year in 2005. and present a "strawman" set of viewgraphs on Thirteen other states and the District of Columbia the following areas to act as the basis for the dis- have adopted or are in the process of adopting sim- cussions: ilar legislation, which could increase that total to • Objectives 400,000 EV per year. Some estimates give the to- tal industry to be billion by the end of the EV S8 • Performance specifications century. Another impact of the legislation is the potential for Hybrid Electric Vehicles (HEV) to • Current technical, economic, and commercial satisfy the requirements for Ultra Low Emission barriers Vehicles (ULEV). • Potential technical solutions and opportuni- The purpose of the workshop was to concen- ties for development trate on the technologies to improve the design, performance, manufacturability, and economics of • Requirements and developments needed for the critical components for the next generation improved manufacturing of Electric Vehicles and Hybrid Electric Vehicles for the year 2000 and beyond. Nearly 200 rep- • Schedule/timetable for EV and HEV compo- resentatives from the automobile manufacturers, nent development aerospace companies, parts suppliers, universities, • Requirements of future standards/test proce- electric utilities, and state and federal govern- dures ment agencies and laboratories attended the work- shop. The workshop was sponsored by the Ad- The session reports in these proceedings include vanced Technology Program at NIST, and orga- discussion and summaries by the session chairs, to- nized through the Interagency Coordination Task gether with the expanded versions of these view- Force on Electric and Hybrid Vehicle Technolo- graphs and other data and papers that were pre- gies. The mission of the Task Force is to coor- sented. dinate and integrate the programs and policies of Presently, the major impetus for EVs and HEVs Federal agencies in developing, testing, and pro- is from the environmental legislature for clean air moting electric and hybrid vehicles and their as- and reduced auto emissions. There also will be sociated technologies. The Task Force includes additional impetus from the recent announcement members from the Departments of Energy, Com- by the Clinton Administration of an agreement to merce, Defense, Transportation and Interior, the work collaboratively with the three U.S. automo- National Aeronautics and Space Administration, bile companies on the New Generation of Vehi- National Science Foundation, Environmental Pro- cles which will have three times the fuel efficiency tection Agency, Office of Science and Technol- of present internal combustion engine autos. In ogy Programs, and Interagency Advanced Power order for EVs and HEVs to successfully compete Group. with the Internal Combustion Engine (ICE), these The Workshop began with invited speakers to vehicles must match the performance as well as cover the general topics: impact of the Califor- offer advantages of fuel economics and reduced nia legislation. Federal agency programs, devel- or zero emissions, without any sacrifice on safety, opment of standards, infrastructure needs, ad- warranty or convenience of use. There is clearly iii iv Executive a market for these vehicles, although this will re- age systems provide a power boost when needed quire a significant financial investment by the auto to the primary energy system which fulfills the en- companies and suppliers. It is possible that the ergy storage for range. There was general agree- market may initially develop in specialty areas, ment at the workshop that not enough attention such as fleets, vans, autos for limited in-town use, is being paid to the development of small engine niche autos, and vehicles for the military. How- technology to be used to replenish the energy for ever, it is important to note that hybrids are also the hybrid systems; these small engines would be being considered and tested for buses. For suc- running at near optimum conditions for fuel ef- cessful deployment of EVs, it is necessary to have ficiency and reduced emissions. It was also felt an infrastructure, including charging stations and that there should be attention to hydrogen fueled suitable standards. It is somewhat ironic to note or enriched fuel systems as a transitional technol- that in 1912 there were 34,000 electric vehicles reg- ogy from gasoline engines to other types of energy istered in the United States and an infrastructure conversion systems. Proton
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