Hybrid/Electric Drive Vehicles

Fairfax, Virginia March 23, 2011

This workshop made possible through support from the U.S. Department of Energy and partners.

Materials for the Clean Transportation Education Project were developed by the NC Solar Center/NC State University and partners with funding from the U.S. Dept of Energy Clean Cities program. The U.S. Government does not assume any legal liability, responsibility for the accuracy, completeness, or usefulness of any information provided, nor endorse any particular product through this support. Topics to be covered today

• Review of hybrid technology • Plug in and EV technology overview • Charging technology • Range anxiety • New models coming to market • Heavy duty hybrids Technology Transportation is becoming a mix of technologies taking us toward sustainability through fuel economy (efficiency), advanced power-trains and idle reduction

3 The Future of Transportation Hybrids & Electric Vehicles!!

4 What is a Hybrid Electric Vehicle?

• A hybrid is a vehicle powered by two or more power- sources of differing technologies, drawing on the key benefits of each power-source to maximize efficiency - Typically an internal combustion engine (ICE) and one or more electric motors - The ICE can be powered by gasoline or diesel or alternative fuels - A fuel cell can be used in place of the ICE • Hybrids also carry two or more sources of energy- liquid fuel for the ICE and battery pack for electrical storage

5 2000 Honda Insight

• First hybrid vehicle available to consumers in the United States

• The InsightPhoto Courtesy Carquest carried an EPA rating of 70 MPG hwy. 61 city

Courtesy of Honda Motor Sales, U.S.A 6 Hybrid Terminology-Components

Full Hybrid = These have two Motor/Generators, Battery Pack, DC/DC Converter, Inverter, Converter & Control Electronics • Battery acts as a storage medium for electricity. Provides electricity during acceleration, stores electricity during regenerative braking and normal charging • DC/DC converter replaces the conventional alternator, provides current for the 12 volt system • Inverter, converter & electronics provide DC/AC and AC/DC current, all controlled by the electronics package

7 Hybrid Technology-The Full Hybrid

Full Hybrids have two Motor/Generators (MGs): First MG starts the ICE & generates electricity to recharge batteries and run accessories.

Courtesy of Toyota Motor Sales, U.S.A Second MG drives wheels & generates electricity • Toyota Hybrid System during regenerative (THS) braking. • Basic design of this system also used by

FordCourtesy & Nissan of Toyota Motor Sales, U.S.A 8 Full Hybrid Detail

Ford Escape Hybrid cutaway

Motor- generator 1

Planetary Gearset

Motor- generator 2 9 Electrically Continuously Variable Transmission - ECVT

Motor/Generator 2 (MG2)

Motor/Generator 1 (MG1)

Planetary Gear Set (Power Split Device)

Differential

Courtesy of Toyota Motor Sales, U.S.A

10 High Voltage Battery Pack 330 Volt NiMH Battery

Courtesy of Toyota Motor Sales, U.S.A This technology is used in the following 2010 models: • Ford Fusion, Escape • Lexus GS450h, RX450h, HS250h & LS600h • Mercury Milan, Mariner • Nissan Altima

• Toyota Camry, Highlander, Prius 11 GM-BMW-Chrysler Partnership General Motors, Daimler Chrysler & BMW joined forces to develop the first two-mode full hybrid system Used primarily to improve fuel efficiency of their least efficient vehicles Features: • Two 60 KW motors • 300-volt battery pack • Electronics, Inverter & Converters similar to full hybrids • V-8 engine with Displacement on Demand, cam phasing, late-intake valve closure and very high compression ratio

• 25-percent composite improved fuel economy 12 2-Mode Hybrids (GM, Daimler, BMW)

This technology is used in the following 2010 models: • BMW X6 • Cadillac Escalade • Chrysler Aspen • Dodge Durango • GMC Sierra, Yukon • Mercedes-Benz ML350, S400

Graphic: SAE

13 Hybrid Terminology Mild Hybrid = Engine (ICE) drives the wheels, electric Motor-Generator functions as a starter motor, adds power to wheels (torque), and generates electricity during regenerative braking (which is stored in the batteries)

• Honda Integrated Motor Assist (IMA), Daimler use the mild hybrid approach, also known as Integrated Starter Generator (ISG) • Allows idle stop – ICE shuts off at stop lights • This technology is used in the Honda Civic, Insight (2010)

14 BAS Hybrid System • Idle stop mode with quick restart on brake pedal release This technology is used in the • Momentary acceleration boost following 2010 models: • Optimized battery charging • Saturn Aura, Vue • Regenerative braking

Photo courtesy General Motors

16 BAS Mild Hybrid System

• Belt Alternator Starter (BAS) Hybrid System • Over 110 lb-ft of auto-start torque • 36/42V motor/generator is on the belt drive • 3000 watts of continuous power • 10 kW of power from the 42-volt NiMH battery • Up to a 10% increase in fuel economy • Other components similar

to mild hybrids 17 Hybrid Electric Vehicle Rules

• The HEV electric motor/generator is typically used to assist the ICE and act as a starter motor

• Some parallel hybrids can be driven by the electric motor/generator only for short periods of time (electric launch)

• An electric motor/generator cannot power the vehicle and charge the battery at the same time

18 Charging Technology

• Electric Vehicles (Plug in, Extended Range & Battery Electric Vehicles) will all share common charging technology • Three levels of charging are being established based upon available supply voltage • The higher the supply voltage, the faster the charge rate

19 Plug In Hybrid Electric Vehicles (PHEV)

• Plug In Hybrids (PHEV) are similar to full Hybrids • PHEV’s utilize a Lithium- Ion Battery Pack which has sufficient electrical storage to propel the vehicle unassisted for 10 to 40 miles • PHEVs can be plugged into a 120/220 VAC outlet to receive its charge • The range of a PHEV battery is noted in the vehicle description. When the Battery in a PHEV has exhausted its charge Example; the Toyota Prius the vehicle will become a conventional hybrid! PHEV-10 20 Plug In Hybrid Electric Vehicles (PHEV) • Toyota is testing a fleet of 150 PHEVs • These are PHEV-10 vehicles (10 mile EV range)

• 20 Ford Escape PHEVs are undergoing validation by Southern California Edison

21 Graphic: Ford Motor Co. Extended Range Electric Vehicles (EREV)

• The Volt is not a PHEV. • 340 Volt Lithium- It is an EREV. The ion batteries difference is significant • 1.4 Liter gasoline engine • The Volt does not have • Engine only significant regenerative generates braking capability electricity, not connected to drive train

22 Chevy Volt Layout/Design

Graphic courtesy General Motors 23 Battery Electric Vehicles (EV or BEV) • Nissan’s LEAF first large volume manufacturer to enter the marketplace • 300 Volt platform • Lithium Batteries • EVs operate on batteries alone • There is no ICE in an EV! • EVs require Inverter, Converter & Electronics similar to hybrids

24 Overcoming “Range Anxiety”

• Range anxiety is the fear on the part of the driver that the EV may run out of power before reaching the destination or a charge station • Range anxiety has been identified as a major concern of potential EV buyers/users • SAE estimates 13,000 public charging stations should be operating by 2012 (10% the number of gasoline stations) • LEAF EPA window sticker range rating is 73 miles • Actual range will vary from 60 to 100 miles • 72% of motorists drive less than 50 miles/day during the week, this drops to 66% on weekends 25 “Range Anxiety” Solutions Nissan LEAF incorporates several features: • Continuous readout of remaining range • Climate control algorithm calculates range with and without heat or A/C • “Range Circle” superimposed on navigation system map • “ECO Mode” provides pushback to the throttle, encouraging using less power on acceleration, also makes regenerative braking more aggressive. Engages as soon as foot released from throttle • Preconditioning of cabin temperature before unplugging • Cold weather package includes thermal blanket for Batteries, seat and steering wheel heaters

26 Charging Plug-In Vehicles

The industry has agreed up upon a single charging connection standard – SAE J1772 for Levels 1 & 2

Charge Times Charge Times Voltage Phase Peak Current Likely Current (medium battery) (large battery) AC Level 1 120 V Single 16 A 12 A 8-12 hours 16-20 hours AC Level 2 208/240 V Single 80 A 30 A 2-3 hours 6-8 hours

DC Fast Under Development – Target 80% “fill” in 30 minutes (e.g. 480 V, 100 A, 48 kW Direct Current Level 1 can utilize a standard household outlet and stand AC Line 2 alone cord set, but Level 2 AC Line 1 requires a hardwired cord set Proximity into a control box with safety Detection electronics.

Control Pilot Ground

27 Mike Waters, Advanced Transportation, Progress Energy Level 3 Charging • Level 3 charging can charge an EV battery from below a 20% SOC to >80% SOC in about 30 minutes • This is accomplished at 480 Volts ( which is not available in homes) • The onboard rectifiers and controls are not adequate to handle this amount of power so rectification to direct current must be performed at the charge station • Level 3 chargers cost up to JARA type connector, capable of $36,000 and will likely be only Level 3 used in public and commercial locations

Grahic: Jama 28 Charging Safety • The proximity detection circuit ensures that current will not be present in the cord/connector until it is securely connected to the vehicle. ( 1kHz square wave at 12 volts ) • The interconnection will also disable the vehicle until the connector is disconnected • This safety feature requires a wall mounted control unit. This is why all Level 2 chargers will require this unit be installed • The J-1772 should have a service life of more than 25 years (10,000 operating cycles)

29 Source: Automotive News Charging Infrastructure: Links

• Coulomb Technologies: www.chargepointamerica.com • EATON Pow-R-Station: www.eaton.com/electrica/usa • ECOtality Blink: www.blinknetwork.com • GE Wattstation: www.geindustrial.com/products/static/wattstation • EV Solutions: http://evsolutions.avinc.com/ • GoSmart Technologies: www.gosmarttechnologies.com • Leviton: http://evergreenchargers.com • OpConnect: www.opconnect.com

Source: Automotive News 30 Coming Soon---

• Vehicles scheduled to launch by 2013 include: – Audi R8 EV (2012) – BMW ActiveE, just launched in Geneva – BYD EV & PHEV Crossovers (2012) – Coda EV (late 2011) – Fiat 500 EV (2012) – Fisker PHEV to launch this month – Ford Transit Connect EV in production, 2012 Focus EV to launch late 2011 (Will launch in Richmond & DC) – GM’s Chevy Volt EREV in show rooms, Cadillac SRX PHEV in 2013

Source: Automotive News 31 Coming Soon---

• Vehicles scheduled to launch by 2013 include: – Honda Fit EV (2012) – Infiniti EV (2013) – Mazda2 EV (2012) – Mercedes SLS AMG EV (2013) – Mitsubishi iMiEV will launch this year – Nissan Leaf EV in showrooms – Smart EV now in pre-production, will launch in 2012 – Tesla EVs in show rooms, crossover to launch in 2013

Source: Automotive News 32 Coming Soon--- • Vehicles scheduled to launch by 2013 include: – Think EV will begin retail sales this year in selected cities – Toyota plans RAV4 EV with Tesla powertrain by 2012, also will roll out the Scion iQ next year – VW E-Up, Golf & Jetta Ev’s available by 2013 along with the XL1, a PHEV – Volvo planning a PHEV Diesel V60 Wagon late 2013 – Wheego will introduce LiFe EV this month, other models to follow – ZAP will launch its A380 EV SUV in June, roadster in September 33 Source: Automotive News Coming Soon---

PHEV or EREV ALL ELECTRIC ? ?

Nissan Leaf Mitsubishi iMIEV GM PHEV Chevrolet Volt Toyota Prius Smart

? Production

Cadillac Converj BYD 3DFM Fisker Karma Ford Focus Ford Transit Tesla Connect

VW Golf Ford Escape PHEV BMW Concept Chrysler/Fiat EV

TwinDrive Mini-E Subaru R1e Demo/Concept Hyundai Blue-Will Volvo C30 Kia Ray Mercedes BlueCell Tesla Model S Toyota FT-EV

Mike Waters, Advanced Transportation, Progress Energy 34 The Rule of “3”

• At today’s level of technology, each 1000 watt/hours of battery capacity can drive the vehicle about 3 miles • This assumes use of A/C, heater and other accessories at same rate as conventional vehicle • A Nissan LEAF has a battery capacity of 24,000 Watts • To apply the rule of “3” multiply the rated battery capacity by 3! 24 X 3 = 72 • The Leaf will have an average range of 72 miles. This figure is in line with test results • Use this rule when considering an EV or PHEV purchase!

35 Battery Technology Battery Technology Developments • Li-ion current battery of choice, although with multiple chemistries • Cost expected to drop to $250-350/kWh by 2020 • Improvement expected in economies of scale, manufacturing, durability, power density and range

Mike Waters, Advanced Transportation, Progress Energy 36 Energy Densities & Fuel Choices

In comparison to other fuel choices, both fossil and renewable, the energy density of batteries, both in weight and volume, remains

a challenge % Carbon %

% Hydrogen

37 Heavy Duty Hybrid Electrics

Dave Navey, Charlotte Truck Center

38 Major Components

POWER ELECTRONICS DIESEL ENGINE HYBRID DRIVE UNIT CARRIER (PEC)

AC/DC INVERTER HYBRID COOLING DC/DC CONVERTER 5 kW APG (OPTIONAL) SYSTEM ePTO ONLY 39 Dave Navey, Charlotte Truck Center H.D. Hybrid Example: Duke Energy

• M2-106 straight truck GVW – up to 40K • Cummins ISB – 200 to 300hp / 520 to 660 ft-lb • Eaton Parallel Electric Hybrid Performance (dependent on stationary PTO Drive – 60hp/310 lb-ft peak usage) • 6 speed Ultrashift • Fuel Economy Improved 40% - 60% • Idle Time Reduced by 4 / 5 Hours per Day transmission • CO2 Output Reduced 13 to 17 Tons/Year • Air Brakes Financial: Federal Tax Credit Class 6 = $6K Class 7 = $12K www.afdc.energy.gov/afdc/laws/law/US/394 Dave Navey, Charlotte Truck Center 40 Heavy Duty Hybrid Summary

• Works best with stationary, PTO operation, applications • Series / Parallel system allows for 3 operational modes: engine only, motor only & engine / motor combination operation • 20% - 60% better fuel economy during PTO operation • Reduces emissions of NOx, 30-40% & particulates 50% as compared to conventional diesel vehicle www.navc.org/Navc9837.pdf • Provides more torque for quicker acceleration & more pulling power • Greatly increases brake life & extends engine life

41 High Voltage Battery Cell

• NiMH electrolyte is typically Potassium Hydroxide (Lye) • This is a very strong base • Neutralize with large amounts of water or a mild acid such as Citric Acid • Li-ion batteries have a variable pH range. Neutralize with large amounts of water • Always refer to the “Emergency Response Guide” available on the manufacturers website!

42 Electricity: Grid adds to fuel choice

Electric Grid Capacity to Displace: PNNL study indicated that current grid can handle 83% of today’s vehicles as plug-in hybrids , reducing oil imports by 50%

Mike Waters, Advanced Transportation, Progress Energy 43 US Electrical Generation Mix

Fossil Fuels

Nuclear, Hydro & Geo Biofuels Wind-Solar Nuclear et al coal Wind & Solar Nat Gas oil

Biofuels

0 10 20 30 40 50 60

Source: BP Statistical Review of World Energy, 2010 44 Virginia’s Energy Mix • Virginia accounts for nearly 10 percent of U.S. coal production east of the Mississippi River. • Virginia’s only petroleum refinery, in Yorktown, processes foreign crude oil delivered by barge via the Chesapeake Bay. • Virginia has two nuclear power plants, which typically provide about one-third of the electricity generated within the State. • Two of Virginia’s coalbed methane fields are among the top 100 natural gas fields in the United States. • Virginia established a voluntary renewable portfolio goal that encourages utilities to generate 12 percent of base-year 2007 sales from renewable sources by 2022. www.eia.gov/cfapps/state/state_energy_profiles.cfm?sid=VA Additional Thoughts…

• Grants and tax credits available: – Up to $7,500 credit on light duty vehicles; 50% on infrastructure – Multiple grants programs “in the works” for infrastructure • Consider fuel and maintenance savings in total cost • Plug-in vehicles help with fleet EPAct credits • Assess your needs and identify the best technology

46 Guide for Economical Choices:

• http://www.afdc.energy.gov/afdc

• http://www.fueleconomy.gov/feg/FE G2000.htm

• www.virginiaev.org

With permission, Automotive News & Leo Michael Thanks for your kind attention! This presentation available at: www.altfueled.org 47