Hybrid Electric and Plug-in Hybrid Electric Vehicle Testing Activities

James FrancfortUS DOE’s Advanced Vehicle Testing Activity (AVTA)Idaho National Laboratory (INL)

2

AVTA Background and GoalThe AVTA is part of the U.S. Department of Energy’s Office of Vehicle TechnologiesThe AVTA is conducted by the INL and Electric Transportation Applications (ETA - Phoenix, AZ), with Argonne National Laboratory performing dynamometer testing

AVTA Goal► Provide benchmark data to technology modelers,

R&D programs, and target setters ► Assist fleet managers in making informed vehicle

purchase, deployment and operating decisions

3

AVTA Testing HistoryHydrogen internal combustion engine vehicles► 6 models, 400,000 test miles

Full-size electric vehicles ► 40 EV models, 5+ million test miles

Neighborhood electric vehicles► 15 models, 200,000 test miles

Urban electric vehicles► 3 models, 1 million test miles

4

Baseline Performance TestingClosed track testing ► Coastdown (dynamometer coefficients), charging,

acceleration, top speed, and durability testsDepending on vehicle technology, a two- to five-day dynamometer testing regime is used:► Urban Dynamometer Driving Schedule (UDDS) and

Highway Fuel Economy Test (HWFET) primary dynamometer tests

► Charge depleting and sustaining test cycles► Includes air conditioning (AC) off and on cycles► Hot and cold starts► PHEV testing includes at least 26 drive cycle tests

5

Onroad Fleet and Accelerated TestingHEVs are tested for 160,000 miles and three years in high mileage fleetsPHEVs are initially onroad tested in defined 10-mile city and highway loops for 5,440 miles, and placed in fleetsMission selection based on vehicle performance characteristics, fuel use, and technology subsystems

6

Hybrid Electric Vehicle (HEV) Testing

7

12 HEV models baseline tested to dateBaseline Performance MPG (J1634 With & W/O Air)

0

5

10

15

20

25

30

35

40

45

50

55

60

Insight Gen IPrius

Gen I Civic Gen IIPrius

Silverado Accord Escape Highlander RX400h Gen IICivic

Camry Vue Average

Mile

s pe

r Gal

lon

MPG SAE J1634 Air On MPG SAE J1634 Air Off

8

HEV Percentage mpg decrease - A/C onPercent MPG Difference (J1634 With & W/O Air)

-30%

-25%

-20%

-15%

-10%

-5%

0%

Insight Gen IPrius

Gen I Civic Gen IIPrius

Silverado Accord Escape Highlander RX400h Gen IICivic

Camry Vue Average

Per

cent

MP

G D

ecre

ase

9

HEV AccelerationHEV Acceleration 0 to 60 MPH

11.7 11.310.4

12.0

9.7

11.5

8.5 8.6 8.89.6

13.9 14.3

0123456789

101112131415

Gen I C

ivic

Insigh

tGen

I Priu

sGen

II Priu

sSilv

erad

o

Escap

e

Accord

Highlan

der

RX400h

Camry

Gen II

Civic

VueS

econ

ds

*0 to 50 mph for Insight, Civic and Gen I Prius. 0 to 60 mph for others

10

HEV Maximum SpeedsMaximum Speeds

0

10

20

30

40

50

60

70

80

90

100

110

120

Gen I Civic Insight Gen IPrius

Gen IIPrius

Silverado Escape Accord Highlander RX400h Camry Gen IICivic

Vue

Mile

s pe

r Hou

r

Max Speed 6% Grade Max Speed 1/4 Mile

11

HEV Normalized CapacityNormalized Capacity Discharge During SAE J1634

0

0.5

1

1.5

2

2.5

3

3.5

Insight Gen I Prius Gen I Civic Gen II Prius Silverado Accord Escape Highlander RX400h Camry Gen II Civic Vue

Cap

acity

Dis

char

ge

AC Off AC On

12

HEVs in Onroad Testing

Not Started?200X GM 2-mode vehicles

Ongoing22006 Gen II Honda Civic

Ongoing22007 Saturn Vue

Ongoing22007 Toyota Camry

37 to dateTotal test or in testing

Ongoing2200X Nissan Altima

Ongoing22006 Toyota Highlander (AWD)

Ongoing32006 Lexus RX 400h (front & 2 AWD)

Ongoing22005 Honda Accord

Completing22005 Ford Escape (front & 4-WD)

Completing22004 Gen II Toyota Prius

Ongoing22004 Chevrolet Silverado (2- & 4-WD)

Completed42003 Gen I Honda Civic

Completed62002 Gen I Toyota Prius

Completed62001 Honda Insight

13

3.2 Million HEV Onroad Test MilesAll HEVs - Miles Driven Monthly & Cumulative

0

250,000

500,000

750,000

1,000,000

1,250,000

1,500,000

1,750,000

2,000,000

2,250,000

2,500,000

2,750,000

3,000,000

3,250,000

Aug-

01Se

p-01

Oct

-01

Nov

-01

Dec

-01

Jan-

02Fe

b-02

Mar

-02

Apr-

02M

ay-0

2Ju

n-02

Jul-0

2Au

g-02

Sep-

02O

ct-0

2N

ov-0

2D

ec-0

2Ja

n-03

Feb-

03M

ar-0

3Ap

r-03

May

-03

Jun-

03Ju

l-03

Aug-

03Se

p-03

Oct

-03

Nov

-03

Dec

-03

Jan-

04Fe

b-04

Mar

-04

Apr-

04M

ay-0

4Ju

n-04

Jul-0

4Au

g-04

Sep-

04O

ct-0

4N

ov-0

4D

ec-0

4Ja

n-05

Feb-

05M

ar-0

5Ap

r-05

May

-05

Jun-

05Ju

l-05

Aug-

05Se

p-05

Oct

-05

Nov

-05

Dec

-05

Jan-

06Fe

b-06

Mar

-06

Apr-

06M

ay-0

6Ju

n-06

Jul-0

6Au

g-06

Sep-

06O

ct-0

6N

ov-0

6D

ec-0

6Ja

n-07

Feb-

07M

ar-0

7Ap

r-07

May

-07

Jun-

07Ju

l-07

Aug-

07Se

p-07

Mile

s

0

10,000

20,000

30,000

40,000

50,000

60,000

70,000

80,000

90,000

100,000

110,000

120,000

130,000

Mile

s

Monthly Mileage (right axis)

Cumulative Mileage (left axis)

14

Onroad Test miles per HEV modelTotal HEV Fleet / Accelerated Reliability Test Miles - By HEV Model

0

50,000

100,000

150,000

200,000

250,000

300,000

350,000

400,000

450,000

500,000

Civic

Insigh

tGen

I Priu

sSilv

erad

oAcc

ords

Gen II

Prius

Escap

es

Lexu

sHigh

lande

r

Camry

Gen II

Civic

Saturn

VueM

iles

Yellow bar = testing complete

15

Onroad Miles per gallon by HEV modelHEV Fleet / Accelerated Reliability Testing MPG - By HEV Model

37.6

45.2

41.0

17.7

28.1

44.2

27.1

23.7 24.6

33.3

39.5

27.8

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

45.0

50.0

Gen I C

ivic

Insig

htGen

I Priu

sSi

lvera

do

Acco

rds

Gen II

Prius

Esca

pes

Lexu

s RX40

0hHigh

lande

r

Camry

Gen II

Civic

Satu

rn V

ueM

iles

per G

allo

n

Yellow bar = testing complete

16

HEV Monthly miles per gallonHEV Monthly Miles per Gallon

15

20

25

30

35

40

45

50

55

Aug-

01Se

p-01

Oct

-01

Nov

-01

Dec

-01

Jan-

02Fe

b-02

Mar

-02

Apr-

02M

ay-0

2Ju

n-02

Jul-0

2Au

g-02

Sep-

02O

ct-0

2N

ov-0

2D

ec-0

2Ja

n-03

Feb-

03M

ar-0

3Ap

r-03

May

-03

Jun-

03Ju

l-03

Aug-

03Se

p-03

Oct

-03

Nov

-03

Dec

-03

Jan-

04Fe

b-04

Mar

-04

Apr-

04M

ay-0

4Ju

n-04

Jul-0

4Au

g-04

Sep-

04O

ct-0

4N

ov-0

4D

ec-0

4Ja

n-05

Feb-

05M

ar-0

5Ap

r-05

May

-05

Jun-

05Ju

l-05

Aug-

05Se

p-05

Oct

-05

Nov

-05

Dec

-05

Jan-

06Fe

b-06

Mar

-06

Apr-

06M

ay-0

6Ju

n-06

Jul-0

6Au

g-06

Sep-

06O

ct-0

6N

ov-0

6D

ec-0

6Ja

n-07

Feb-

07M

ar-0

7Ap

r-07

May

-07

Jun-

07Ju

l-07

Aug-

07Se

p-07

Mile

s pe

r Gal

lon

Insight Gen I Civic

Gen I Prius Gen II Prius

Silverado Accord

Escape RX400h

Highlander Camry

Gen II Civic Vue

17

Onroad HEV testing and EPA MPGHEV Fleet Testing MPG

101214161820222426283032343638404244464850525456586062

Gen I Civic Insight Gen I Prius 4WDSilverado

2WDSilverado

AccordsGen II Prius 4WDEscape

2WDEscape

AWDRX400h

2WDRX400h

AWDHighlander

Camry Gen II Civic Vue

Mile

s pe

r Gal

lon

AVTA Fleet EPA New Combined EPA Old Combined

18

Onroad HEV testing and EPA MPGPercent EPA MPG > or < AVTA Fleet MPG

-12%-10%

-8%-6%-4%-2%0%2%4%6%8%

10%12%14%16%18%20%22%24%26%28%30%32%34%

4 '0

3 C

ivic

6 '0

1 In

sigh

ts

6 '0

2 &

'03P

rius

1 '0

4 4W

DSi

lver

ado

1 '0

4 2W

DSi

lver

ado

2 '0

5 A

ccor

ds

2 '0

4 Pr

ius

1 '0

5 4W

D E

scap

e

1 '0

5 2W

D E

scap

e

2 '0

6 A

WD

Lex

usR

X400

h

1 '0

6 2W

D L

exus

RX4

00h

2 '0

6 A

WD

Hig

hlan

der

2 '0

7 C

amry

2 '0

6 C

ivic

2 '0

7 Sa

turn

Vue

Ave

rage

New EPA > AVTA Old EPA > AVTA

19

HEV Maintenance and Repairs

20

HEV Life-Cycle Costs per MileHEV Cost per Mile

$0.00

$0.10

$0.20

$0.30

$0.40

$0.50

$0.60

$0.70

$0.80

$0.90

04 P

rius

160k

04 P

rius

159.

9k

04 S

ilver

ado

88k

04 S

ilver

ado

85k

05 A

ccor

d 13

4k

05 A

ccor

d 13

8k

06 H

ighl

ande

r 124

k

06 H

ighl

ande

r 52k

05 E

scap

e 15

6k

05 E

scap

e 14

8k

06 R

X40

0h 1

18k

06 R

X40

0h 8

2k

06 C

ivic

66k

06 C

ivic

81k

07 C

amry

82k

07 C

amry

50k

07 V

ue 5

4k

07 V

ue 1

2k

Wht

Ave

rage

Cos

t per

Mile

Maintenance Costs

Ownership Costs

Operating Costs

Operating costs = fuel, insurance & registration

21

Plug-in Hybrid Electric Vehicle (PHEV) Testing

22

EnergyCS Prius – UDDS EnergyCS PHEV Prius MPG & kWh - UDDS Testing

0

1020

30

4050

60

7080

90

100110

120

130140

150

160170

180

7 15 22 30 37 45 52 60 67 75 82 90 97 105 112 120 127 135 142 150

Each Bar = 1 UDDS Test Cycle. Labeled by Cumulative Miles

MP

G

0

0.51

1.5

22.5

3

3.54

4.5

55.5

6

6.57

7.5

88.5

9

kWh

Drive Cycle MPG Cumulative AC kWh Cumulative MPG

23

EnergyCS Prius – HWFETEnergyCS PHEV Prius MPG & kWh - HWFET Testing

0

1020

3040

50

6070

8090

100

110120

130

140150

160170

180

10 21 31 41 51 62 72 82 92 103 113 123 133 144 154

Each Bar = 1 HWFET Test Cycle. Labeled by Cumulative Miles

MP

G

0

0.51

1.52

2.5

33.5

44.5

5

5.56

6.5

77.5

88.5

9

kWh

Drive Cycle MPG Cumulative AC kWh Cumulative MPG

24

Hymotion Prius – UDDSHymotion PHEV Prius MPG & kWh - UDDS Testing

01020

30405060

708090

100110

120130140150

160170180

7 15 22 30 37 45 52 60 67 75 82 90 97 105 112 119 127 134 142

MPG

0.00.51.0

1.52.02.53.0

3.54.04.55.05.5

6.06.57.07.5

8.08.59.0

Each Bar - 1 USSD Test Cycle, Labeled by Cumulative Miles

kWh

MPG per UDDS Test Cumulative AC kWh Cumulative MPG

25

Hymotion Prius – HWFETHymotion PHEV Prius MPG & kWh - HWFET Testing

0102030405060708090

100110120130140150160170180

10 21 31 41 51 62 72 82 92 103 113 123 133 144 154

MPG

0.00.51.01.52.02.53.03.54.04.55.05.56.06.57.07.58.08.59.0

Each Bar - 1 HWFET Test Cycle, Labeled by Cumulative Miles

kWh

MPG per FWHET Test Cumulative MPG Cumulative AC kWh

26

Accelerated PHEV Onroad TestingUses dedicated driversPredetermined and repeatable drive cyclesCombinations of urban and highway loops5,440 total onroad test miles per PHEV model162 drive and charging cycles that include 1,344 hours of charging - can not economically be performed on a dynamometerNot as controlled as dynamometer, but compliments controlled dynamometer testing by allowing a broader view of fuel use over many more miles and charging events

27

Accelerated PHEV Onroad Testing

188.357%43%Average

5,4401621,3443,1002,340Total

11%2%600312182200

11%4%60061282100

12%5%6408126280

11%6%60010124260

11%9%60015124040

11%9%60015122240

11%9%60015120440

11%19%6003081120

11%37%6006040110

(%)(%)(mi)(N)(hr)(10 mi)(10 mi)(mi)

MilesRepsTotalRepsChargeHighwayUrbanCycle

28

EnergyCS Prius – Accelerated Testing

125.64.78115.586006040110

88.4 Weighted Ave424013298425001740Total

57.810.4612.98600312182200

70.88.8122.6760061282100

65.810.0939.046408126280

103.75.9065.0060010124260

85.52.4330.00200*5124040145.11.4229.00200*5122240126.41.6117.37200*512044077.9 7.95 86.216003081120

MPGGalskWh(mi)(N)(hr)(10 mi)(10 mi)(mi)

GasolineElectricityTotalRepsChargeHighwayUrbanCycle

* Being rerun to 600 miles

29

Hymotion Prius – Accelerated Testing

Weighted Ave424013298425001740Total

600312182200

73.238.4335.9860061282100

6408126280

60010124260

60051240406005122240

108.91.8729.84200*5120440115.9 5.37122.026003081120

6006040110MPGGalskWh(mi)(N)(hr)(10 mi)(10 mi)(mi)

GasolineElectricityTotalRepsChargeHighwayUrbanCycle

* Being rerun to 600 miles

30

EnergyCS & Hymotion Fuel Costs/MileFuel Cost per Mile - Hymotion, EnergyCS (UDDS & HWFET) & Other Vehicles

$0.03

$0.04

$0.05

$0.06

$0.07

$0.08

$0.09

$0.10

$0.11

$0.12

$0.13

$0.14

$0.15

$0.16

$0.17

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Each Data Point Labeled by HWFET and UDDS Tests, Uneven Miles. Gas $3.25 gallon & kWh - $0.10

Fuel

Cos

t per

Mile

ECS UDDS Combined $$ PER MILE

ECS HWY Combined $$ PER MILE

HYM UDDS Combined $$ PER MILE

HYM HWY Combined $$ PER MILE

PHEV Prius 45 MPG

ICE Gas 30 MPG

ICE Gas 20 MPG

ECS Prius Accelerated Testing

31

Renault Kangoo – Series hybrid

40.90.042Battery & Gas Hot HWFET

0.48160 Battery Only 10-mile Accelerated Cycles

0.271Battery Only @ Constant 45 mpg

0.110

0.144

0.155

0.268

A/C kWh per Mile

39.4Battery & Gas Hot UDDS

42.3Battery & Gas Cold UDDS

Battery Only - HWFET

Battery Only - UDDS

Miles per GallonTest Cycle

32

Hymotion Charger ProfileHymotion - Pack Charge Profile

196.95

24 .26

4.62

0

50

100

150

200

250

0 2000 4000 6000 8000 10000 12000 14000 16000 18000

Tim e (sec)

Volta

ge -

VDC

0

5

10

15

20

25

30

35

Cur

rent

, Ah,

kW

h

Voltage (V)Current (A)AhkW h

33

Hymotion Charger ProfileHymotion - Pack Charge Profile

161

163

165

167

169

171

173

175

0 50 100 150 200 250 300 350 400 450 500 550 600

Tim e (sec)

Volta

ge -

VDC

0

2

4

6

8

10

12

14

Cur

rent

, Ah,

kW

h

Voltage (V)Current (A)AhkW h

34

Hymotion Charger Profile – Per CellH ym otion - Per Ce ll Charge Pro file

3.50

2.20

7.49

0

0.5

1

1.5

2

2.5

3

3.5

4

0 2000 4000 6000 8000 10000 12000 14000 16000 18000

Time (sec)

Volta

ge V

DC

0

1

2

3

4

5

6

7

8

Cur

rent

, Wh,

Ah

Voltage per C ell(V)Current per Ce ll (A )Ah per C ell (Ah)W h per Ce ll (W h)

35

EnergyCS Charger ProfileEnergyCS - Pack Charge Profile

245.54

4.62

20.77

5.04

0

50

100

150

200

250

0 5000 10000 15000 20000 25000Tim e (s e c)

Volta

ge -

VDC

0

5

10

15

20

25

Cur

rent

, Ah,

kW

h

Voltage (V)Current (A)AhkW h

36

EnergyCS Charger ProfileEnergyCS - Pack Charge Profile

4.62

241

242

243

244

245

246

247

248

16000 16050 16100 16150 16200 16250 16300 16350 16400 16450 16500 16550 16600

Tim e (s e c)

Volta

ge -

VD

C

0

2

4

6

8

10

12

14

Cur

rent

, Ah,

kW

h

Voltage (V)Current (A)AhkW h

37

EnergyCS Charger Profile – Per CellEne rgyCS - Ce ll Cha rge Profile

3.41

0.14

0.63

2.12

0

1

2

3

4

5

6

7

8

9

10

0 5000 10000 15000 20000 25000

Tim e (sec)

Volta

ge -

VDC

0.0

0.5

1.0

1.5

2.0

2.5

Cur

rent

, Ah,

Wh

Voltage per Cell (V)Current per Cell (A)Ah per Cell (Ah)W h per Cell (W h)

38

NYSERDAThe AVTA is testing New York State Energy Research and Development Agency’s PHEVs

Delivered once, sent backHybridsPlus Escape

4 deliveries requiredAfter baselineStartingElectovaya Escape

Delivered Albany, NYHymotion Escape

Not yet deliveredHymotion Civic

DeliveredongoingCompletedHymotion Prius

DeliveredNear completionCompletedEnergyCS Prius

Delivery StatusAcceleratedBaselineModel

39

Seattle-Area Demonstration13 Hymotion Prius PHEV demonstration with:► The City of Seattle (4)► King County (4)► Port of Seattle (2)► Puget Sound Clean Air Agency (3)

Testing will include charging and driving profiles as well as charging infrastructure analysisStart late 1st quarter CY2008

40

City of TacomaThe City of Tacoma has obtained 1 lead acid battery Prius PHEV from the Green Car Company with 1 more on order, and 1 Hymotion Prius is on orderTacoma and the AVTA to conduct cooperative testing of vehicles and charging infrastructure► Tacoma is following the NEC for PHEV charging► Each branch circuit is metered

Testing will include charging and driving profiles as well as charging infrastructure analysisStarted 4th quarter CY2007

41

NRECADeveloping PHEV data collection effort with National Rural Electric Cooperative AssociationTotal of 7 Prius and Escape PHEVs from Hymotion, EnergyCS, and HybridsPlus will be operated by rural electric coop utilities in Florida, Georgia, Indiana, Minnesota, North Carolina, Oregon, and South Carolina The AVTA will collection and process onboard data from the fleets, and provide individual vehicle and fleet operations dataTesting will include charging and driving profiles as well as charging infrastructure analysis

42

HymotionData loggers installed on most of 50 PHEVs in 25 North America locations, with plans to actively collect data on 100 vehicles during 2008New battery version available in 1st quarter 2008, is in crash testing and will have SULEV certificationTesting will include charging and driving profiles as well as charging infrastructure analysisThe AVTA signed agreement with Hymotion and is initiating Hymotion fleet testing support

43

EnergyCSThe AVTA and EnergyCS have signed and initiated a data collection, dissemination and reporting agreementEnergyCS has provided historical PHEV operations onboard data for 7 vehicles operating in fleets in Canada, Arizona, and California

44

EnergyCS Onboard DataEnergyCS Prius - 678 Miles of Driv es and Charging Ev ents

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

1 956 1911 2866 3821 4776 5731 6686 7641 8596 9551 10506 11461 12416 13371 14326 15281 16236 17191

RPM

, Ah

In a

nd A

h O

out

0

50

100

150

200

250

300

350

400

450

500

Volta

ge a

nd S

peed

(mph

)

RPM Ahi Aho Speed Voltage

INL/CON-07-12227

This work is supported by DOE’s Office of Vehicle Technologies

- Vehicle Systems Team Leader, Tien Duong- AVTA DOE Lead, Lee Slezak

http://avt.inl.gov or

http://www1.eere.energy.gov/vehiclesandfuels/avta/