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Medium- and Heavy-Duty Vehicle Electrification an Assessment of Technology and Knowledge Gaps

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Medium- and Heavy-Duty Vehicle Electrification an Assessment of Technology and Knowledge Gaps ORNL/SPR-2020/7 Medium- and Heavy-Duty Vehicle Electrification An Assessment of Technology and Knowledge Gaps (December 2019) ORNL/SPR-2020/7 Medium- and Heavy-Duty Vehicle Electrification An Assessment of Technology and Knowledge Gaps Oak Ridge National Laboratory (ORNL) and National Renewable Energy Laboratory (NREL) December 2019 ORNL: David Smith, Ron Graves, Burak Ozpineci, P. T. Jones NREL: Jason Lustbader, Ken Kelly, Kevin Walkowicz, Alicia Birky, Grant Payne, Cory Sigler, Jeff Mosbacher Contents List of Figures ................................................................................................................................................. v List of Tables ................................................................................................................................................ vii Acknowledgments ........................................................................................................................................ ix Acronyms ...................................................................................................................................................... xi Executive Summary .................................................................................................................................... xiii 1 Introduction ........................................................................................................................................... 1 1.1 Study Purpose.............................................................................................................................. 1 1.2 Scope ........................................................................................................................................... 1 1.3 Report Organization .................................................................................................................... 2 2 Industry Overview .................................................................................................................................. 2 2.1 Medium and Heavy-Duty Vehicle Industry Characterization ...................................................... 2 2.2 Growth of Electrification in the Medium and Heavy-Duty Vehicle Sector ................................. 4 2.3 Summary of Available Electrified Commercial Vehicle Medium and Heavy-Duty Vehicle Electrification Inventory ................................................................................................. 5 3 Medium- and Heavy-Duty Vehicle Hybrid and Electric Architectures ................................................. 10 3.1 48 V Mild Hybrids ...................................................................................................................... 12 3.2 High Voltage Full Hybrids, including Plug-In Hybrid Electric Vehicles ....................................... 13 3.3 Fuel Cell Hybrids ........................................................................................................................ 15 3.4 Battery-Only Electric.................................................................................................................. 16 3.5 Distinguishing Aspects of Electrification of Commercial Medium- and Heavy-Duty Vehicles vs. Electric Passenger Cars .......................................................................................... 20 4 Important Factors in Design and Market Uptake of Electrified Commercial Vehicles ........................ 22 4.1 Total Cost of Ownership ............................................................................................................ 22 4.1.1 Review of total cost of ownership analyses ................................................................. 23 4.1.2 Findings ........................................................................................................................ 24 4.2 Duty Cycle Impact on Vehicle Design and Total Cost of Ownership ......................................... 28 5 Industry Perspectives on Technical Gaps and Barriers to Electrification ............................................ 34 5.1 Gaps and Barriers Identified by Technology Users and Customers .......................................... 35 5.2 Gaps and Barriers Identified by Vehicle, Powertrain, and Component Manufacturers ........... 36 6 Status of Components for Electrification ............................................................................................. 37 iii 6.1 Introduction ............................................................................................................................... 37 6.2 Electric Drive Overview ............................................................................................................. 38 6.2.1 Major components ....................................................................................................... 39 6.2.2 State of the art for electric power components .......................................................... 40 6.2.3 Technology gaps in power electronics devices ............................................................ 41 6.3 Motors-Inverters ....................................................................................................................... 43 6.3.1 Motors .......................................................................................................................... 44 6.3.2 Integrated traction drives and e-axles ......................................................................... 47 6.4 Electrical Energy Storage ........................................................................................................... 48 6.4.1 Current state of the art ................................................................................................ 49 6.4.2 Energy storage technology gaps .................................................................................. 51 6.5 Electrified Accessories ............................................................................................................... 53 6.5.1 State of the art ............................................................................................................. 54 6.5.2 Electrified accessories technology gap ........................................................................ 55 6.6 Chargers ..................................................................................................................................... 56 6.6.1 Current state of the art ................................................................................................ 56 6.6.2 Other charging systems ................................................................................................ 58 6.6.3 Charging technology gap .............................................................................................. 58 6.7 Summary of Electrification Component Technology, Knowledge Gaps, and R&D Needs ......................................................................................................................................... 58 7 Conclusions .......................................................................................................................................... 60 References ................................................................................................................................................... 62 Appendix A ................................................................................................................................................. A-1 iv List of Figures Figure ES1: Energy use by weight class for Class 3 through Class 8 battery electric vehicles..................... xv Figure ES2: Medium- and heavy-duty vehicle battery capacity by weight class for Class 3 through Class 8 battery electric vehicles. ..................................................................................................... xv Figure 1: Commercial vehicle weight classes ................................................................................................ 3 Figure 2: Classifications used for commercial vehicles (medium- and heavy-duty vehicles). ...................... 3 Figure 3: Approximate new sales of commercial vehicles across the weight classes 2b–8. ......................... 4 Figure 4: Reduction in battery costs enhances opportunities for electrified medium- and heavy- duty vehicles. .................................................................................................................................... 5 Figure 5: Medium- and heavy-duty vehicle electrification inventory. .......................................................... 7 Figure 6: Battery capacity vs. weight class for select medium- and heavy-duty vehicles............................. 7 Figure 7: Inventory of medium- and heavy-duty vehicle battery chemistries. ............................................. 8 Figure 8: Range vs. battery energy for various classes of electrified medium-and heavy-duty vehicles. ............................................................................................................................................ 8 Figure 10: Peak electric motor power vs. fuel converter power for various electrification architectures and internal combustion engines. .............................................................................. 9 Figure 11: Trade-offs between common lithium ion chemistries. .............................................................. 10 Figure 12: Schematic representation of the relative electric machine positioning
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