U.S. Department of Energy -Advanced Vehicle Testing Activity

Hybrid Electric, Plug-in Hybrid Electric, and Hydrogen Internal Combustion Engine Testing Activities

Intermountain Conference on the Environment

Idaho State University, September 2007Jim Francfort

2

Presentation• INL and AVTA background, history and goal• Test methods• Testing Results

– Hybrid electric vehicles (HEVs) – Plug-in hybrid electric vehicles (PHEVs)– Hydrogen station and hydrogen internal

combustion engine (HICE) vehicles• Webpage address for this presentation and ~300 test

reports and fact sheets

3

Idaho National Laboratory• The INL is an Eastern Idaho

based U.S. Department of Energy (DOE) multi-program laboratory conducting research, development and demonstrations to help “ensure the nation’s energy with safe, competitive and sustainable energy systems…..”

• Managed for DOE by Battelle Energy Alliance

• 61 patent applications and 4 R&D 100 awards in 2006

• 890 square mile site with 3600 staff

Nuclear

Wind

Geothermal

Bio-mass

Hydropower

Fossil Energy

4

AVTA Background and Goal• The Advanced Vehicle Testing Activity (AVTA) is part

of the U.S. Department of Energy’s FreedomCAR and Vehicle Technologies Program

• The AVTA is primarily conducted by the Idaho National Laboratory (INL) and Electric Transportation Applications (ETA - Phoenix, AZ), with Argonne National Laboratory performing dynamometer testing

• AVTA Goal– Provide benchmark data to technology modelers,

research and development programs, and target setters

– Assist fleet managers in making informed vehicle purchase, deployment and operating decisions

5

AVTA Testing History• Plug-in hybrid electric vehicles

– 3 models tested, 4 more starting• Hybrid electric vehicles

– 12 models, 3 million test miles• Hydrogen ICE (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

6

Baseline Performance Testing • Initial closed track testing conducted near Phoenix, AZ

– Testing includes coastdown (determination of dynamometer coefficients), acceleration, top speed, charging, and durability tests

• Depending on vehicle technology, a two- to five-day dynamometer testing regime is used that includes:– Urban Dynamometer Driving Schedule (UDDS) and

Highway Fuel Economy Test (HWFET) primary dynamometer test cycles

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

7

Fleet and Accelerated Testing • Technology dependant

– PHEVs are onroad tested in defined 10-mile city and highway loops for 4,240 miles

– HEVs are tested for 160,000 miles and three years in high mileage fleets

– HICEs in tested in private and utility fleets (hydrogen infrastructure fueling limited)

8

Hybrid Electric Vehicle (HEV) Testing

9

HEV Baseline Performance Testing • 12 HEV models baseline performance tested to date

Baseline 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

10

HEV Baseline Performance Testing • Percentage mpg decrease with air conditioning on

Percent 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

Perc

ent M

PG D

ecre

ase

11

HEV Accelerated Testing HEV Model Number Accelerated Tested Accelerated Testing Status

2001 Honda Insight 6 Completed

2002 Gen I Toyota Prius 6 Completed

2003 Gen I Honda Civic 4 Completed

2004 Chevrolet Silverado (2- & 4-WD) 2 Ongoing

2004 Gen II Toyota Prius 2 Completing

2005 Ford Escape (front & 4-WD) 2 Completing

2005 Honda Accord 2 Ongoing

2006 Lexus RX 400h (front & 2 AWD) 3 Ongoing

2006 Toyota Highlander (AWD) 2 Ongoing

2006 Gen II Honda Civic 2 Ongoing

200X GM 2-mode vehicles ? ?

2007 Saturn Vue 2 Ongoing

2007 Toyota Camry 2 Ongoing

200X Nissan Altima ? Obtaining

Total 35 to date

12

HEV Accelerated Testing• 2.9 million total accelerated testing miles

All 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

3,000,000Au

g-01

Sep-

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Feb-

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May

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Jun-

02Ju

l-02

Aug-

02Se

p-02

Oct

-02

Nov

-02

Dec

-02

Jan-

03Fe

b-03

Mar

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Apr-

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Jul-0

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Sep-

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Feb-

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4Ap

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May

-04

Jun-

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l-04

Aug-

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p-04

Oct

-04

Nov

-04

Dec

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Jan-

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b-05

Mar

-05

Apr-

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Jul-0

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Sep-

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ct-0

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Feb-

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ar-0

6Ap

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May

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Jun-

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Aug-

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p-06

Oct

-06

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-06

Dec

-06

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07Fe

b-07

Mar

-07

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07M

ay-0

7

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

Mile

s

Monthly Mileage (right axis)

Cumulative Mileage (left axis)

13

HEV Accelerated Testing• Test miles per HEV model

Total HEV Fleet Test Miles

0

50,000

100,000

150,000

200,000

250,000

300,000

350,000

400,000

450,000

500,000

Civic Insight Gen I Prius Silverado Accord Gen IIPrius

Escape RX400h Highlander Camry Gen IICivic

Vue

Tota

l Tes

t Mile

s by

Mod

e

14

HEV Accelerated Testing• Miles per gallon by HEV model

HEV Fleet Testing MPG

37.6

45.2

41.0

17.8

28.3

44.2

27.3

24.0 24.8

33.2

40.1

29.0

0

5

10

15

20

25

30

35

40

45

50

Gen I Civic Insight Gen I Prius Silverado Accord Gen IIPrius

Escape RX400h Highlander Camry Gen IICivic

Vue

Mile

s pe

r Gal

lon

15

HEV Accelerated Testing• Monthly miles per gallon

HEV 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

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Sep-

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ct-0

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ov-0

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Feb-

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ar-0

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May

-07

Mile

s pe

r Gal

lon

Accord Insight

Gen I Civic Gen I Prius

Gen II Prius Silverado

Escape RX400h

Highlander Camry

Gen II Civic Vue

16

HEV Accelerated Testing• AVTA accelerated testing and EPA miles per gallon

HEV 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

17

HEV Maintenance and Repairs Tracked

18

HEV Life-cycle Costs• Ownership, operating, and maintenance costs per mile

HEV Cost per Mile

$0.00

$0.10

$0.20

$0.30

$0.40

$0.50

$0.60

$0.70

$0.80

$0.9004

Priu

s 16

0k

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

X400

h 11

8k

06 R

X400

h 82

k

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

19

Plug-in Hybrid Electric Vehicle (PHEV) Testing

• Can be a currently available HEV that has been converted to a PHEV by adding a second battery pack or using a larger replacement battery pack. Vehicle converters and OEMs are using both methods in series and parallel configurations

• Several OEMs have also announced future products • Different from HEVs in that PHEVs must be plugged

into the electric grid to charge, usually via a 110 volt, 15 amp circuit, the larger PHEV battery packs

PHEV Status and Brief Description

20

21

PHEV Baseline Performance Testing

22

EnergyCS Prius – UDDS Fuel Use• 9 kWh Valence lithium pack – A/C kWh

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 – HWFET Fuel Use• 9 kWh Valence lithium pack – A/C kWh

EnergyCS 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

MPG

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 – UDDS Fuel Use• 5 kWh A123 lithium and Prius packs – A/C kWh

Hymotion 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 – HWFET Fuel Use• 5 kWh A123 lithium and Prius packs – A/C kWh

Hymotion 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

EnergyCS Prius – Fuel CostsEnergyCS PHEV Prius UDDS & HWFET Fuel Cost per Mile

$0.000

$0.005

$0.010

$0.015

$0.020

$0.025

$0.030

$0.035

$0.040

$0.045

$0.050

$0.055

$0.060

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

Each Data Pioint Labeled by HWFET and UDDS Tests, uneven miles. Gas $3.25 gallon & kWh $0.10

Fuel

Cos

t per

Mile

ECS UDDS $ per Mile Gas

ECS UDDS $ per Mile kWh

ECS HWY $ per Mile Gas

ECS HWY $ per Mile kWh

ECS UDDS Combined $$ PER MILE

ECS HWY Combined $$ PER MILE

27

Hymotion Prius – Fuel CostsHymotion PHEV Prius UDDS & HWFET Fuel Cost per Mile

$0.000

$0.005

$0.010

$0.015

$0.020

$0.025

$0.030

$0.035

$0.040

$0.045

$0.050

$0.055

$0.060

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

Each Data Pioint Labeled by HWFET and UDDS Tests, uneven miles. Gas $3.25 gallon & kWh $0.10

Fuel

Cos

t per

Mile

HYM UDDS $ per Mile Gas

HYM UDDS $ per Mile kWh

HYM HWY $ per Mile Gas

HYM HWY $ per Mile kWh

HYM UDDS Combined $$ PER MILE

HYM HWY Combined $$ PER MILE

28

EnergyCS Prius PHEV Accelerated TestingCycle Urban Highway Charge Reps Total Electricity Gasoline

(mi) (10 mi) (10 mi) (hr) (N) (mi) kWh Gals MPG10 1 0 4 60 60020 1 1 8 30 600 86.21 7.95 75.5 40 4 0 12 5 200 17.37 1.61 124.240 2 2 12 5 200 29.00 1.42 140.840 0 4 12 5 200 30.00 2.43 82.360 2 4 12 10 600 65.00 5.90 101.780 2 6 12 8 640 39.04 10.09 63.4

100 2 8 12 6 600 22.67 8.81 68.1200 2 18 12 3 600 12.98 10.46 57.4

Total 1740 2500 984 132 4240

29

Combined ECS and Hymotion Fuel CostsFuel 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

30

Other PHEV Test Vehicles and Partners• PHEVs to be tested

– Electrovaya Escape, Hymotion Civic and Escape, and HybridsPlus Escape (all lithium batteries)

• PHEV demonstration and testing partners– NYSERDA (New York State Energy Research and

Development Agency)– Seattle area: City of Seattle, Seattle City Light, King

County, Port of Seattle, Puget Sound Clean Air Agency

– Tacoma Public Utilities– Southern California Edison– State of Hawaii

31

Hydrogen Internal Combustion Engine (HICE) Vehicle Testing

32

APS Alternative Fuel (Hydrogen) Pilot Plant• Partners - Arizona Public Service (APS), Electric

Transportation Applications (ETA), INL, & DOE• First & longest operating hydrogen station in the

U.S. – since June 2002• Hydrogen produced onsite• Hydrogen & CNG fueling

33

Pilot Plant - Layout

Hydrogen Fuel Cell

2 H2 High psi tanks

H2 Low psi tank

H2 Compressor

2 CNG Compressors

6 CNG Tanks @ 3 psi levels)

34

Pilot Plant - Hydrogen SubsystemsOxygen

Water H2

Compressor High Pressure Storage

Low Pressure StorageDryerH2 Generator

Filter

Electricity

H2 Out

35

Pilot Plant – Hydrogen Subsystems cont’d• Proton Energy Systems’ HOGEN PEM stationary fuel

cell operating in reverse• Hydrogen Lectrodryer• Hydrogen compressor• Norman hydrogen filters• Hydrogen - 99.9997% purity

36

Pilot Plant - Hydrogen Subsystems cont’d• Low pressure hydrogen storage (lower tank)

– 8,955 SCF @ 150 psi• High pressure hydrogen storage (upper 2 tanks)

– 17,386 SCF @ 6,000 psi (total both tanks)

37

Pilot Plant - CNG Subsystem

Boost CompressorMain Compressor

CNG Output

Street Service Low

PressureNatural Gas

High Pressure Storage (3 levels)

38

Pilot Plant - CNG Subsystem cont’d• CNG Boost Compressor

– 300 scfm @ 60 psi • CNG Main Compressor

– 350 scfm @ 5,000 psi• CNG Storage/Pressure – 6 tanks

– 3 Low: 11,079 scf @ 3,600 psi– 2 Medium: 5,711 scf @ 4,500 psi– 1 High: 5,711 scf @ 5,000 psi

39

Pilot Plant - Fueling Dispensers• Includes metering & electronic billing interface• Fully permitted for motor fuel dispensing• Public access

40

15% HCNG Dodge Van Emissions Testing• 5.2 L CNG V8 (no modifications) with 71,000 HCNG test

miles - no problems - 15.5 miles/GGE

Percentage change in 15% HCNG emissions compared to 100% CNG emissions

Total hydrocarbons -34.7%

Carbon monoxide -55.4%

Oxides of nitrogen +92.1%

Carbon dioxide -11.3%

41

30% HCNG F150 Testing• 5.4 L V8 CNG base engine – added supercharger,

ignition modifications & exhaust gas recirculator• Fleet testing HCNG miles: 17.3 miles/GGE

Fuel Blend 0 to 60 mph (secs.) Miles/GGE Range (miles)

CNG 10.10 23.3 122

15% HCNG 10.97 22.6 110

30% HCNG 12.68 23.5 102

42

30% HCNG F150 Emissions TestingPercentage Change in Emissions TestingFuel

Type NMHC CH4 HC CO NOX CO2

Gasoline Base Base Base Base Base Base

CNG -80 +967 +35 -63 -34 -24

15% HCNG -78 +1000 +40 -70 -26 -27

30% HCNG -89 +1050 +37 -73 -25 -28NMHC=Non-Methane Hydrocarbons CH4=MethaneHC=Total Hydrocarbons CO=Carbon MonoxideNOx=Oxides of Nitrogen CO2=Carbon Dioxide

43

50% HCNG F150 Emissions Testing• Modifications

– SVO heads, exhaust intercooler & supercharger– Exhaust gas recirculator & ignition modification– Equipped with 3 Quantum hydrogen 3,600 psi tanks

with 9 kg total storage

Percent reduction in emissions (HCNG versus gasoline-fueled F-150)

HC CO NOX CO2

-3.5% -43.3% -97.0% -16.7%

HC = total hydrocarbonsCO = carbon monoxideCO2 = carbon dioxideNOx = oxides of nitrogen

44

5.4L 16-valve 100% Hydrogen ICE Vehicle• 5.4L V-8, 100% hydrogen 16-valve Ford/ETEC pickup• 5 speed transmission, supercharged (3 psi), lean-burn• Onboard hydrogen storage 3 Dynetek tanks @ 3,000

psi, 6.5 kg, aluminum vessel & fiberglass wrap• SAE J1634 fuel economy (AC on): 14.5 miles/GGE• SAE J1634 fuel economy (AC off): 18.0 miles/GGE• Fleet testing – 18.5 miles per GGE (120 miles range)

45

5.4L 32-valve 100% Hydrogen ICE Vehicle• 5.4L V-8, 100% hydrogen 32-valve Ford/ETEC pickup• 12 pounds supercharger boost, with hardened valves

& seats, and forged pistons with 11.5:1 compression• 13.0 miles per GGE in fleet testing• Onboard hydrogen storage 3 Dynetek tanks @ 5,000

psi, 15.3 kg (200-mile range)

46

6L V-8 100% Hydrogen ICE Vehicle• Base vehicle: Chevrolet 1500HD crew cab (4 door)

with 6L V8 CNG engine, converted by ETEC/Roush to 100% hydrogen

• 10.5 kg 100% hydrogen storage onboard @ 5,000 psi• 200 Horsepower & 260 lb-ft torque• 14 city & 20 highway miles per GGE - range of 140 to

200 miles• Eight vehicles in fleet testing in Vancouver B.C.

47

AcknowledgementThis work is supported by DOE’s

FreedomCAR and Vehicle Technologies ProgramVehicle Systems Team Leader, Tien Duong

AVTA DOE Lead, Lee Slezak

http://avt.inl.govAdditional Information

INL/CON-07-13004