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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/