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Powertrain Technology and Cost Assessment of Battery Electric Vehicles Powertrain Technology and Cost Assessment of Battery Electric Vehicles by Helen Qin A Thesis Submitted in Partial Fulfillment of the Requirements for the Degree of Master of Applied Science in Automotive Engineering In the Faculty of Engineering and Applied Science University of Ontario Institute of Technology Oshawa, Ontario, Canada, 2010 © Helen Qin, 2010 Library and Archives Bibliothèque et Canada Archives Canada Published Heritage Direction du Branch Patrimoine de l’édition 395 Wellington Street 395, rue Wellington Ottawa ON K1A 0N4 Ottawa ON K1A 0N4 Canada Canada Your file Votre référence ISBN: 978-0-494-62010-6 Our file Notre référence ISBN: 978-0-494-62010-6 NOTICE: AVIS: The author has granted a non- L’auteur a accordé une licence non exclusive exclusive license allowing Library and permettant à la Bibliothèque et Archives Archives Canada to reproduce, Canada de reproduire, publier, archiver, publish, archive, preserve, conserve, sauvegarder, conserver, transmettre au public communicate to the public by par télécommunication ou par l’Internet, prêter, telecommunication or on the Internet, distribuer et vendre des thèses partout dans le loan, distribute and sell theses monde, à des fins commerciales ou autres, sur worldwide, for commercial or non- support microforme, papier, électronique et/ou commercial purposes, in microform, autres formats. paper, electronic and/or any other formats. The author retains copyright L’auteur conserve la propriété du droit d’auteur ownership and moral rights in this et des droits moraux qui protège cette thèse. Ni thesis. Neither the thesis nor la thèse ni des extraits substantiels de celle-ci substantial extracts from it may be ne doivent être imprimés ou autrement printed or otherwise reproduced reproduits sans son autorisation. without the author’s permission. In compliance with the Canadian Conformément à la loi canadienne sur la Privacy Act some supporting forms protection de la vie privée, quelques may have been removed from this formulaires secondaires ont été enlevés de thesis. cette thèse. While these forms may be included Bien que ces formulaires aient inclus dans in the document page count, their la pagination, il n’y aura aucun contenu removal does not represent any loss manquant. of content from the thesis. Abstract This thesis takes EV from the late 90’s as a baseline, assess the capability of today’s EV technology, and establishes its near-term and long-term prospects. Simulations are performed to evaluate EVs with different combinations of new electric machines and battery chemistries. Cost assessment is also presented to address the major challenge of EV commercialization. This assessment is based on two popular vehicle classes: subcompact and mid-size. Fuel, electricity and battery costs are taken into consideration for this study. Despite remaining challenges and concerns, this study shows that with production level increases and battery price-drops, full function EVs could dominate the market in the longer term. The modeling shows that from a technical and performance standpoint both range and recharge times already fall into a window of practicality, with few if any compromises relative to conventional vehicles. Electric vehicles are the most sustainable alternative personal transportation technology available to-date. With continuing breakthroughs, minimal change to the power grid, and optimal GHG reductions, emerging electric vehicle performance is unexpectedly high. ii Acknowledgements I would like to thank my advisor Dr. Greg Rohrauer, whose wisdom, guidance and mentoring has guided me throughout my study and the writing of this thesis. Direct funding support from Auto21 and benefits of involvement with EcoCAR: the NeXt Challenge is graciously acknowledged. I would also like to thank my parents for their patience and support. iii Table of Contents List of Figures .................................................................................................................... vi List of Tables ................................................................................................................... viii List of Abbreviations ......................................................................................................... ix 1. Introduction ................................................................................................................. 1 2. Battery Technology ..................................................................................................... 8 2.1. Lead acid battery .................................................................................................. 8 2.2. Nickel-based Battery ............................................................................................ 9 2.2.1. Nickel Cadmium Battery .............................................................................. 9 2.2.2. Nickel metal hydride Battery ...................................................................... 11 2.3. Lithium-based Battery ........................................................................................ 12 2.4. Automotive Application ..................................................................................... 15 2.5. Battery Safety ..................................................................................................... 24 2.6. Conclusion .......................................................................................................... 28 3. Analysis Methodology .............................................................................................. 30 3.1. Vehicle road test ................................................................................................. 36 4. Vehicle Simulations using Advanced Batteries ........................................................ 46 4.1. Electric Vehicles in the 90’s ............................................................................... 47 4.1.1. GM EV1 ...................................................................................................... 47 4.1.2. Chevy S-10 EV ........................................................................................... 47 4.1.3. Ford Ranger EV .......................................................................................... 48 4.1.4. Chrysler EPIC ............................................................................................. 48 4.2. EV Baseline Performance Goals ........................................................................ 48 4.3. PSAT Simulation Results ................................................................................... 51 4.4. EVs employing Advanced Battery Technology ................................................. 52 4.5. New vehicle with advanced battery technology ................................................. 55 5. Electric Motors .......................................................................................................... 58 5.1. DC Motors .......................................................................................................... 58 5.2. Induction Motors ................................................................................................ 60 5.3. Synchronous Machines (Brushless DC) ............................................................. 63 5.4. Electric Machines Modeled ................................................................................ 63 5.5. Motor Modeling Results..................................................................................... 68 6. Sensitivity Study ....................................................................................................... 70 6.1. Battery ................................................................................................................ 70 iv 6.2. Motor efficiency ................................................................................................. 74 6.3. Accessory load ................................................................................................... 78 6.4. Drive schedules for fuel economy testing .......................................................... 81 7. Electric Vehicle Cost Assessment ............................................................................ 85 7.1. Cost related Parameters ...................................................................................... 85 7.2. Battery Pack Cost Breakdown ............................................................................ 90 7.3. Vehicle Cost ....................................................................................................... 97 8. Conclusion .............................................................................................................. 108 8.1. Recommendations ............................................................................................ 111 References ....................................................................................................................... 112 Appendix A. EVAmerica Tested EVs ............................................................................ 117 Appendix B. Vehicle Specification ................................................................................. 125 Appendix C. Drive Cycles .............................................................................................. 126 Appendix D. PSAT Input ................................................................................................ 130 v List of Figures Figure 1-1, Series hybrid electric drivetrain, plug-in
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