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Hybrid/Electric Drive Vehicles 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
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