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Deliverable 6.2 Performance Validation Deliverable 6.2 Performance validation - Results from EV measurements Prepared by: Bart Benders, fka [email protected] Kim Winther, DTI [email protected] Morten Holst, DTI [email protected] Christian Kolf, TÜV NORD Mobilität [email protected] Date: December 16th, 2014 Version: 1.5 GA MOVE/FP7/265499/Green eMotion Deliverable 6.2 Page 1 of 127 Document Information Authors Name Company Key author Bart Benders fka Further authors Kim Winther DTI Morten Holst DTI Christian Kolf TÜV NORD Mobilität Distribution Dissemination level PU Public x PP Restricted to other programme participants (including the Commission Services) RE Restricted to a group specified by the consortium (including the Commission Services) CO Confidential, only for members of the consortium (including the Commission Services) Revision history Version Date Author Description 1.0 Mai 27th, 2013 Bart Benders Template 1.1 June 3rd, 2013 Morten Holst First complete draft 1.2 July 28th, 2014 Christian Kolf Dynamometer measurements 1.3 November 3rd, 2014 Bart Benders Final Version 1.4 December 12th, 2014 Luis de Prada Internal review 1.5 December 16th, 2014 Kim Winther Submission for approval Status Status For Information Draft Version Final Version (Internal document) Submission for Approval (deliverable) x Final Version (deliverable, approved on) GA MOVE/FP7/265499/Green eMotion Deliverable 6.2 Page 2 of 127 Table of Contents 1 Executive Summary .............................................................................................................. 13 2 Introduction ........................................................................................................................... 14 2.1 Work package 6 goals and background ................................................................................ 14 2.2 Alignment between partners ................................................................................................. 15 3 Performance validation of electric vehicles ........................................................................... 17 3.1 State of the art of electric vehicles ........................................................................................ 17 3.1.1 Main components ................................................................................................................. 23 3.1.2 Layout ................................................................................................................................... 26 3.1.3 Safety Aspects ...................................................................................................................... 29 3.2 Hypothesis and their analysis ............................................................................................... 37 3.3 On road performance validation ............................................................................................ 38 3.4 Climate impact, dynamometer measurements ...................................................................... 39 4 Analysis of hypothesis, on road performance validation ....................................................... 40 4.1 Test track conditions ............................................................................................................. 40 4.2 Vehicles used in the on-road tests ........................................................................................ 45 4.3 Theory in short ...................................................................................................................... 46 4.4 Hypothesis 1: Range and consumption are mainly dependent on drive pattern .................... 48 4.4.1 Steady speed ........................................................................................................................ 49 4.4.2 Dynamic driving .................................................................................................................... 51 4.4.3 Full acceleration ................................................................................................................... 54 4.4.4 Combinations of dynamic and steady driving ........................................................................ 56 4.4.5 Aggressive driving ................................................................................................................ 59 4.4.6 Drive train comparison - ICE vs. EV ..................................................................................... 62 4.5 Hypothesis 2: Range and consumption depend strongly on the use of auxiliaries ................ 65 4.6 Hypothesis 3: SOH is predictable by step response testing .................................................. 70 4.7 Hypothesis 4: Climate has significant impact on battery performance .................................. 71 4.7.1 Charging losses .................................................................................................................... 72 4.8 Hypothesis 5: Battery performance is almost unaffected by battery charge rate ................... 74 GA MOVE/FP7/265499/Green eMotion Deliverable 6.2 Page 3 of 127 4.9 Hypothesis 6: Heating and defrosting capacity is adequate .................................................. 76 4.10 Hypothesis 7: Regenerative braking adds significantly to vehicle range ............................... 78 4.11 Hypothesis 8: Safety functions are maintained in the event of empty battery ....................... 84 4.12 Hypothesis 9: Optimum regenerative braking relies on battery and motor parameters ......... 86 4.13 Hypothesis 10: Vehicle performance is almost unaffected by battery SOH ........................... 87 4.13.1 Vehicle performance compared to conventional ICE vehicles .............................................. 91 4.14 Hypothesis 11: Propulsion energy is largely unaffected by climate conditions ...................... 93 4.14.1 The impact of temperature .................................................................................................... 94 4.14.2 The impact of wind ............................................................................................................... 96 4.14.3 The impact of rain ................................................................................................................. 98 4.14.3.1 Smoothening the surface ................................................................................................................ 99 4.14.3.2 Increase in air mass due to the presence of rain drops ................................................................ 100 4.14.3.3 Increased cooling of tires ............................................................................................................. 101 4.14.3.4 Auxiliary energy needed to work the wind shield wipers. .......................................................... 101 4.14.3.5 Energy required for water expulsion on surface .......................................................................... 102 4.14.4 The impact of slope ............................................................................................................ 103 4.14.5 The impact of weight .......................................................................................................... 104 5 Validation and analysis of climatic impact ........................................................................... 108 5.1 Analysis of influence of temperature and aging on charging efficiency and battery capacity108 5.1.1 Charging behaviour ............................................................................................................ 108 5.1.2 Influence of temperature ..................................................................................................... 110 5.1.3 Influence of aging ............................................................................................................... 113 5.2 Analysis of influence of temperature and auxiliary loads on vehicle performance ............... 114 5.3 Validation of driving cycles ................................................................................................. 117 5.4 Validation of CAN data ....................................................................................................... 119 5.5 Validation of SORDS measurements .................................................................................. 123 6 Technical conclusions......................................................................................................... 124 7 Overall conclusions ............................................................................................................ 127 GA MOVE/FP7/265499/Green eMotion Deliverable 6.2 Page 4 of 127 List of Figures Figure 3.1.1: Renault Twizy ZE ................................................................................................................. 17 Figure 3.1.2: Daimler Smart Fortwo ED .................................................................................................... 17 Figure 3.1.3: Mitsubishi i-MiEV ................................................................................................................. 18 Figure 3.1.4: Renault Fluence ZE ............................................................................................................. 18 Figure 3.1.5: Nissan Leaf .......................................................................................................................... 19 Figure 3.1.6: BMW i3 ...............................................................................................................................
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