U.S. Department of Energy -Vehicle Technologies Program 2008 Annual Merit Review

Advanced Vehicle Testing Activity (AVTA) – Non-PHEV Evaluations and Data Collection

Vehicle Systems Merit ReviewJim Francfort – INL AVTA Principle InvestigatorLee Slezak – DOE Sponsor

February 2008, Bethesda, Maryland

This presentation does not contain any proprietary or confidential information

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Vehicle Testing Objectives• Overall vehicle testing objectives

– Benchmark and reduce operational uncertainties of emerging vehicle technologies

– Provide testing results to vehicle modelers and technology target setters in support of DOE technology development efforts, and to early adaptor fleet managers

– Continue to utilize Phoenix area test tracks and fleet testing arrangements

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Vehicle Testing Objectives – cont’d• Hybrid Electric Vehicles (HEVs)

– Reduce HEV battery and vehicle uncertainties and document life-cycle costs

• Hydrogen Internal Combustion Engine (HICE) Vehicles– Assess the safety, reliability and operating

characteristics of 100% HICE vehicles– Identify any engine or vehicle system degradations

when operating on hydrogen

4

Vehicle Testing Objectives – cont’d• Neighborhood Electric Vehicles (NEVs)

– Support the California Air Resource Board’s (CARB) decision to require all NEV models sold in California be tested by the AVTA in order to be eligible for CARB incremental funding and credits

• Electric Ground Support Equipment (eGSE)– Support the development, understanding and

deployment of eGSE at domestic airports

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FY07 Testing Accomplishments• Hybrid Electric Vehicles (HEVs)

– Completed baseline performance testing on 12 HEV models to date (five models during FY07)

– As of September 2007, 3.2 million test miles have been accumulated (987,380 miles during FY07) on 19 HEVs in JPMorgan fleet (160,000 miles per vehicle in 3 years, minimum 2 vehicles per model)

– Initiated end of life (EoL) battery testing on two Gen II Prius and two Escape HEVs, having previously completed EoL battery testing on two Gen I Prius, two Gen I Civic, and two Honda Insight HEVs

– Collected fuel economy, maintenance, depreciation, operations (insurance and registration), and other life-cycle related vehicle costs in fleet missions to determine life-cycle costs

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FY07 Testing Accomplishments – cont’d• Hydrogen Internal Combustion Engine (HICE) Vehicles

– Eight 100% HICE pickups (Roush CNG conversions) being fueled at the Integrated Waste Hydrogen Utilization Project (IWHUP) in Vancouver, BC• 16,000 total test miles and 20.1 miles per GGE

with no safety problems• Faster exhaust gas oxygen sensor degradation• Increased presence of water in the engine oils

due to lower combustion temperatures during lean-burn operations

• Increased exhaust manifold corrosion– Roush 100% HICE pickup baseline performance

tested in FY07 (total of 4 HICE and HCNG models tested to date)

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FY07 Testing Accomplishments – cont’d• Neighborhood Electric Vehicles (NEVs)

– CARB and Wisconsin required all NEV models be tested to the AVTA’s NEVAmerica testing procedures

– Initiated the testing of a new NEV from Global Electric Motors (GEM), a Chrysler subsidy

• Electric Ground Support Equipment (eGSE)– Completed baseline performance testing on electric

pushback tractor– Developed economic payback model for baggage

tractors, belt loaders, and pushback tractors propelled by electric motors or petroleum engines (including fueling infrastructure). Based on operations of two airlines at four airports. Partners: EPRI, SCE, SMUD, Georgia Power, Southwest and Delta Airlines

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HEVs in Testing2001 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

2008 GM 2-mode Tahoes 2 Starting

2007 Saturn Vue 2 Ongoing

2007 Toyota Camry 2 Ongoing

2008 Nissan Altima 2 Ongoing

Total test or in testing 39 to date

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

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HEVs Baseline Performance TestedBaseline Performance MPG (J1634 With & W/O Air)

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Percent HEV MPG Decrease - A/C onPercent MPG Difference (J1634 With & W/O Air)

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

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SaturnVue

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

37.6

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HEV Monthly Onroad MPGHEV Monthly Miles per Gallon

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Onroad HEV MPG vs. Old/New EPA MPGHEV Fleet Testing MPG

101214161820222426283032343638404244464850525456586062

Gen I Civic Insight Gen I Prius 4WDSilverado

2WDSilverado

AccordsGen II Prius 4WDEscape

2WDEscape

AWDRX400h

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AVTA Fleet EPA New Combined EPA Old Combined

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Onroad HEV MPG vs. Old/New EPA MPG Percent 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%

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New EPA > AVTA Old EPA > AVTA

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HEV Maintenance and Repairs

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HEV Life-Cycle Costs per MileHEV Cost per Mile

$0.00

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$0.9004

Priu

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ilver

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Maintenance Costs

Ownership CostsOperating Costs

Operating costs = fuel, insurance & registration

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HICEVAmerica Roush Testing Fact Sheet

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NEVAmerica GEM Testing Fact Sheet (Draft)

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eGSEAmerica FMC Pushback Tractor Testing Fact Sheet

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• Continue role as DOE’s whole vehicle system field tester

• Conduct baseline performance, accelerated and fleet testing on new vehicles with new technologies

• Continue to provide feedback to domestic automotive industry and other advanced technology stakeholders

• Continue presentations at industry and public events and disseminating testing results via the www

• FY08 budget is $1,800k, with ~$600k spent to date

FY08 Overall Testing Plans

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FY08 HEV Testing Plans• HEV accessory testing

– Initial FY07 results from “parking lot test”• Camry exhibited ~1.5 kW peak demand• Highlander exhibited ~3.9 kW peak demand• Modeled assumptions are significantly lower

– FY08 expanded testing to include Prius and Escape HEV accessory load testing• Power steering no input and at lock stop• Air conditioning at full compressor load and

defrost compressor load• All optional accessories off at idle (initial

condition) versus maximum blower speed, all accessory loads, power window operation, service brake operation and engine start

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FY08 HEV Testing Plans – cont’d• Initiate baseline performance testing of new HEVs

available during FY08, including the Nissan Altima and two-mode General Motors Tahoe

• Initiate 160,000 accelerated testing on 2 of each Altima and Tahoe HEV models

• Continue accelerated testing on 2 Highlander, 2 Vue, 2 Civics, 2 Camry, and 2 Silverado HEVs

• Conduct beginning of life testing on Tahoe and Altima HEV batteries

• Conduct EoL HEV battery testing (at 160,000 miles) on Escape, Accord, Gen II Prius and Lexus RX400h HEVs

• Continue to analyze data from onboard data loggers• Continue to provide 160,000-mile vehicles and

components to other DOE laboratories for EoL testing

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FY08 Testing Plans• HICE Vehicles

– Continue to operate the eight HICE vehicles fueled at IWHUP and document fuel use, vehicle performance, and any additional effects hydrogen has on vehicle subsystems

– Continue to analyze vehicle performance from onboard data loggers

– Continue to evaluate candidate test vehicles and when appropriate, perform baseline performance and fleet testing on them

• NEVs– Initiate testing on two more GEM NEVs, one ZEN

NEV, and one Miles Automotive NEV– Given the potential of this market and the

expanding use of NEVs, the AVTA will support CARB and continue to test new entrants

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Vehicle Testing Summary• Continue to utilize testing partnerships to provide

maximum test value to DOE– All testing activities are cost shared with private

sector, such as the JPMorgan fleet that operates HEVs for the AVTA

– All NEV and eGSE baseline performance testing is cost shared with manufacturers

• Battery testing results are provided to the energy storage technical team

• HEV testing results are provided to domestic OEMs via the vehicle simulation and analysis technical team every other month

• Testing results and life-cycle costs are used by vehicle modelers

• Partnering with private sector testers provides low-cost access to many testing facilities on a per-need basis

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Vehicle Testing Summary – cont’d• NEV testing for CARB supports higher vehicle

standards in this vehicle segment• AVTA testing results provide independent analysis of

emerging technologies to Federal and other fleets that are early adaptors of advanced vehicle technologies

• Public use of AVTA webpages increases every yearINL WWW Visitors & Gasoline Costs

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Linear (Gasoline Cost (right axis) )Linear (Visitors (left axis))

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AcknowledgementThis work is supported by DOE’s Vehicle Technologies Program

Hybrid Electric Systems Leader, Tien DuongVehicles and Systems Simulation and Testing Leader,

Lee Slezak

http://avt.inl.gov or

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

Additional Information

INL/CON-08-13848