Advancing Plug In Hybrid Technology And Flex Fuel .
Advancing Plug In Hybrid Technologyand Flex Fuel Applicationon a Chrysler Mini-VanPHEV DOE Funded ProjectAbdullah A. BazziChrysler Group LLCMay 11, 2011Project ID # VSS063This presentation does not contain any proprietary, confidential, or otherwise restricted information
RT Project OverviewTimeline Project Start:September, 2009 Project Complete:June, 2014 20% CompleteBudget Total Project Funding DOE: 10,000,000 Chrysler 15,791,697 Funding received FY09: 0 Funding received FY10: 0 Funding received FY11: 1,846,175 Chrysler Program Total: 5,006,976Barriers Battery performance across extremeambient conditions Thermal Management Integration Charging System Integration Flex Fuel Controls and Calibration forPHEV Understanding customer acceptanceand usage patterns for PHEVtechnology*Figures stated are As of: Feb 28, 2011Development Partners : Behr America ElectrovayaDemonstration Partners: Sacramento Municipal Utility District (SMUD) Austin Energy State of Michigan Argonne National LabsThis presentation does not contain any proprietary, confidential, or otherwise restricted information2
RT Program Objectives – Relevance Demonstrate 25 minivans (RT) in diverse geographies andclimates, spanning from Michigan, California, and Texas andacross a range of drive cycles and consumer usage patternsapplicable to the entire NAFTA region Run the vehicles for 2 years with relevant data collected to provethe product viability under real-world conditions Quantify the benefits to customers and to the nation Develop & demonstrate charging capability Develop and demonstrate Flex Fuel (E85) capability with PHEVtechnology. Support the creation of “Green” Technology jobs and advance thestate of PHEV technology for future production integration Develop an understanding of Customer Acceptance & Usagepatterns for PHEV technology Integration of PHEV technology with Renewable energy generationThis presentation does not contain any proprietary, confidential, or otherwise restricted information3
RT Project PlanThis presentation does not contain any proprietary, confidential, or otherwise restricted information4
Plug-in Hybrid Technical SpecificationsChrysler Town & Country TouringThe only minivan to boast a plug-inhybrid powertrain in combination withFlex Fuel (E85) capabilityHybrid Drive SystemTechnology Next Generation Lithium IonBatteryCharge Times 2-4 hrs at 220V 6-8 hrs at 110V Full Hybrid system functionw/o Plug-inFuel Economy (City) Charge Depleting 53 MPGElectric Drive Range (City) 22 miles equivalentRange 700 milesBrakes Regenerative Brake SystemExterior DimensionsVehicle Length 202.5”Overall Height 68.9”Body Width 76.9”Ground Clearance 6.1” @ Curb WeightTrack 65.5” Front 64.8” RearTurning Diameter 38.0’ Curb to CurbWheelbase 121.2”PowertrainEngine 3.6L V6Fuel Flex Fuel (E85) capabilityMaximum Power 290 HorsepowerWheels / TiresWheels 16” x 6.5” AluminumTires 225/65 R16 BSW AllSeasonAdditional Features Dual Power Sliding Doors 2nd Row Stow ‘N Go 3rd Row Stow ‘N Go Satellite / Navigation Radio Engine Block HeaterInterior DimensionsCargo Capacity (behind front seat) 140.1 Cubic FeetPassenger Volume 156.1 Cubic FeetSeating Capacity 7 PassengerCapacities / WeightsCurb 5446 lbsFuel Tank Capacity 20.5 gallonsGCWR 9,050 lbsGVWR 6,250 lbsPayload 1,200 lbsSafetyElectronic Stability Program Traction Control ABS Brake Assist Electronic Roll Mitigation Hill Start Assisted Trailer Sway ControlAir Bags Advanced Multistage Front Supplemental Side Curtain Supplemental Front and RearCurtainChrysler LLC reserves the right to make changes at any time, without notice or obligation, in prices, specifications, equipment, colors and materials, and to change ordiscontinue models. The data contained within this brochure should be regarded as approximate. Please note that some models and options may not be available in allmarkets. The vehicle’s emissions are not fully certified and will have an exemption label displayed.This presentation does not contain any proprietary, confidential, or otherwise restricted information5
Phase I – Technical Actions Design & Package PHEV Components Virtual modeling & Simulation of PHEV technology Component level Bench Testing of new PHEV components,software and calibrations Retrofit Base Gas Vehicle with PHEV Technologyi. Design, Package, and Install Li-Ion Batteryii. Design, Package, and Install Chargeriii. Design, Package, and Install controls for battery thermalmodule, and Power Electronicsiv. Develop controls and calibration for PHEVv. Update remaining thermal system components for PHEVvi. Design, Package, and Install LV & HV Wiringvii. Modify 3.6L Pentastar Engine to accept HybridComponentryviii. Retrofit Vehicle with 2-Mode Hybrid Transmissionix. Instrument vehicle for PHEV testing & validationThis presentation does not contain any proprietary, confidential, or otherwise restricted information7
RT - MilestonesPhase I: PHEV Development – 2009/10/11 Simulate key systems to confirm sub-system technical specificationsBuilt 7 Mini-Vans for Mule Level Engineering Development HV Battery System ( 2 Early Vintage – 5 New Architecture) Thermal System (5) 2 Mode Hybrid Transmission (all) Re-Generative Brake System (5) Engine Controls / Power Electronics (all) Hybrid System Controls (all) Successfully Completed Summer Hot Weather Development Trip TestingSouthwest Quadrant U.S. (Death Valley, Stove Pipe, Bakers Grade, Las Vegas(City Cycle), Phoenix (Chrysler APG) 1st week: Successfully completed vehicle shake down and APGTesting 2nd week: Successfully completed testing and calibrationmodifications 3rd week: Successfully validated software calibration packagesThis presentation does not contain any proprietary, confidential, or otherwise restricted information8
RT - MilestonesPhase 2: Refine Vehicle Verification ObjectivesBuild 9 Development (DV) Vehicles 5 Impact Vehicles 14 DV Vehicles Finalize PHEV component and sub-system designs Supplier selection and component sourcing Perform Vehicle packaging & Structural Enhancements Confirm Key features and functionalities Define system level and vehicle level test plans Develop tooling and procure required equipment Procure Instrumentation equipment Order carrier vehicles for DV Mini-Van BuildHV Battery Packs, HV&LV Wiring , 2 mode Hybrid Transmissions, PowerElectronics, Re-Gen Brakes, Thermal Management Components,Charging System Components, Structural Components Procure all components required for the 14 Development vehicles andbuild 14 Mini-Vans Perform Vehicle level testing on the Mini-Van as part of the PHEV systemcontrols development.This presentation does not contain any proprietary, confidential, or otherwise restricted information9
Technical Accomplishments – Vehicle Build & TestDevelopment and validation utilized the standard Chrysler Group LLCVehicle Development Process for a production intent program Designed and built all development and test vehicles Augmented development process with modified testing proceduresto address specific plug in Hybrid Technologies Facility Based Testing: hot static cell, hot drive cell, cold static cell,cold drive cell, altitude chamber, engine dynamometer, transmissiondynamometer, NHV cell, EMC cell, end of line; bench Testing: vibration,SOC, thermal, charge / discharge cycling Impact Testing: Planned for FMVSS compliance Road trips: development testing and verification: hot trip to 125F, coldtrip to -20F, altitude trip to 12,000 ft Durability testing: Planned for powertrain, high mileage, two chargecycles per day.This presentation does not contain any proprietary, confidential, or otherwise restricted information10
Technical Accomplishments (Cont.)PHEV Specific Feature Development: Thermal management of Li-ion battery system capable of heating the highvoltage battery in extreme cold, and cooling the high voltage battery inextreme hot ambient temperatures, optimizing the operating temp range. Developed powertrain control system to operate within the powerlimitations of the Li-ion battery over ambient temperature range of-20oF to 125oF while providing predictable and reliable vehicle performance Developed charging system capable of charging up to 6.6Kw PHEV systems integrated cold start, cold drive, EV Drive, start/stop, thermalmanagement, battery SOC operational boundaries, level 1 & level 2 torquesecurity validation, transmission dynamometer for E-Motor PHEV drive cycleThis presentation does not contain any proprietary, confidential, or otherwise restricted information11
Technical Accomplishments – FE & EmissionsRANGEEMISSIONS(SIMS Only)FUELECONOMYProposalEquivalent AllElectric Range(EAER) of 22milesTier 2 Bin5Compliancewith Indolene& E-85ChargeDepleting City53 MPGStatusSimulation results have shown that 20 miles EAER can beachieved.ProcedureCalifornia Exhaust EmissionStandards And TestProcedures, as amendedDecember 2, 2009Standards and Internal Goals for FTPProcedures as listed inTITLE 40--Protection ofEmission Limits atEmission Limits at FullEnvironment50,000 milesUseful Life (120,000 miles) CHAPTER I--ENVIRONMENTALTier 2StandardNOx NMOGCONOx NMOGCOPROTECTION AGENCY(g/mi) (g/mi) (g/mi)(g/mi) (g/mi) (g/mi)SUBCHAPTER C--AIRFed Bin 50.050.0753.40.070.094.2PROGRAMSChryslerEmission Limits at 50,000Emission Limits at FullPART 86--CONTROL OFMinivanNOx NMOGCONOx NMOGCOPHEV Target (g/mi) (g/mi) (g/mi)(g/mi) (g/mi) (g/mi) EMISSIONS FROM NEW AND0.0330.0531.70.0460.0632.1IN-USE HIGHWAY VEHICLESAND ENGINES.– FE CITY: Simulation results – 47.7 MPG 16.07SAE J 1711, Date Published:kWh/100mi2010-06-08.» Utility Factors (SAE J 2841) based - CD & CS arecombined and reported as one number; Fuel Energy& Electrical Energy reported separately (no MPGe).» Vehicle kWh/100mi was calculated using a nominalcharging system efficiency of 88%.This presentation does not contain any proprietary, confidential, or otherwise restricted information12
Key Facilities & Equipment Used by Chrysler andDemonstration Partners at Development & Demo SitesChryslerFacilities / InfrastructureAll Existing: Windsor Assembly plant, Windsor, MI Chrysler Technical Center – Auburn Hills, MI– Fuel Economy Testing, Altitude chamber, StaticHot/Cold cell, Environmental Drive cell Chelsea Proving Grounds – Chelsea, MI– Sled-impact testing site, Covered crash barrier, Skidtraction area, Mileage accumulators, Emissionscertification Center, Wind tunnelEquipment : All New ETAS Hardware – Automotive ElectronicControl Unit (ECU) calibration ETK – ECU Interface ES – Measurement and Network Modules INCA Software – ETAS software for ECU calibration Matlab Simulink – General engineering data computationand analysis software CANoe Software – ECU simulation software CANalyzer Software – Analysis tool for data networksand distributed systems 25 EVSE Level 2 Charging Units Deployed to PartnerLocationsPartnersAustin Energy New: Charging Station InfrastructureBehr Existing: Wind Tunnel, Performance lab New: Module impact assembly fixturesElectrovayaSMUDState ofMichigan Existing: System Calorimeter New: Charging Station Infrastructure Existing: Advanced Metering Infrastructure New: Charging Station InfrastructureThis presentation does not contain any proprietary, confidential, or otherwise restricted information13
Vehicle Charging s toCharge Efficiency No Customer InputMinimal System InputHighest Charging rateFleet Vehicle March 2012Implementation Customer InputMax System InputMost Efficient Charge RateData Collection & ReportingDevelopment Start May 2011March 2012 ImplementationThis presentation does not contain any proprietary, confidential, or otherwise restricted information14
Data Reporting – Technical AccomplishmentsInitial Fleet Deployment Implementation – March 2012 Remote Software Flash Remote Diagnostics Near Real Time Data Upload Chrysler’s PHEV server sends the DoE required Unlimited Rights data toIdaho National Labs (INL) for the purpose of data processing and reporting.PHEV ServerInternetIdaho National Labs(INL) ServerCellDoE datapacketUserInterfaceCopy of DoE DataCellExternal InterfaceReporting ServerUser InterfaceOptimized ChargingparDoE PartnersAccess onlyfor their fleetThis presentation does not contain any proprietary, confidential, or otherwise restricted information15
PHEV Mini-Van DemonstrationPartner Vehicle Deployment PlanPartnerState of MichiganSMUD (SacramentoMunicipal Utility District)Austin Energy- ERCOT- UT AustinArgonne National LabFleet ActivityQtyDeployment Date4Mar-12Diverse drive cycle and use10Mar-12Pool vehicles for the city of Austin10Mar-12Technology Evaluation and Testing1Mar-12Cold ClimateDiverse useThis presentation does not contain any proprietary, confidential, or otherwise restricted information16
Future WorkPhase I: PHEV Development Complete Cold Weather Validation of vehicle software, calibration and component testsComplete vehicle durability and validationCalibration/Controls DevelopmentCharging systemHMIi.Hybrid Human Machine Interface (HMI) DisplayPlug-In Charging HMI Displayii. Functional objective verificationi.Fuel reductionii.Flex Fuel Capabilityiii. DrivabilityPhase II: Build and Launch Prep Site preparation – Ship Level 2 EVSE Units for installation at Demonstration Partner DeploymentLocationsCustomer/Dealer trainingBuild the 25 Mini-Van demonstration fleetVehicle Prep and DeliveryPhase III: PHEV Vehicle Demonstration Data Capture / Analysis / Continue Modifications & OptimizationsEnhance Data Reporting CapabilitiesOptimize Charge Development and CalibrationCustomer Interface ServerThis presentation does not contain any proprietary, confidential, or otherwise restricted information18
Summary Official Award received from the DOE October 2010 Management process established. Successful Upgrade of 7 Mule Vehicles Successful Hot Trip Testing On track to meet program milestones and project deliverables. Successful development, execution, and validation of the PHEVtechnology on engineering level vehicles. Successfully demonstrated the PHEV 22 miles All ElectricEquivalent drive cycle. Scheduled FE Testing to support the target fuel economy level of53 mpg in charge depleting cycle (electric equivalent range EAER). On track to meet program milestones and project deliverables. Created “Green” core competency jobs and have a plan in place tosustain them toward future development of electrification programs.This presentation does not contain any proprietary, confidential, or otherwise restricted information19
Technical Back-Up SlidesThis presentation does not contain any proprietary, confidential, or otherwise restricted information20
RT MiniVan PHEV – Battery System SummaryElectrovaya - Major Contributions Design/Engineering /Simulation/Testing/Packaging Cell manufacturing in Mississauga, Ontario. Battery Pack manufacturing in Malta, NewYorkRT – MiniVan Battery SpecificationCell Specs: 96 cells in series360 V nominal pack voltageCell 33.3 Ah Prismatic pouch cellChemistry:Lithium NCM blended cell chemistryEnergy: 12 kWh overall pack energyCharge Charging at up to 6 kW rateCapacity:Thermal Liquid cooled with glycol/waterSystem: coolantPackaging: The battery is packaged in the“Stow-n-Go” tub space.8 kWh useable energy for ChargeDepleting cycle35 kW discharge power during chargedepleting cycleUnique “Heli-cool” battery moduleswith integrated cooling loopLocated between the first and secondrow seats.This presentation does not contain any proprietary, confidential, or otherwise restricted information21
Charging System - SummaryScope/Objective 6.6 KW On-board ChargerTesting and Validation Charging Capability under various ambient temperatures and voltage ranges Power Output: 6.6kW @ 220Vac1.4kW @ 110Vac Network ManagementFlash/read application in vehicleI/O CAN Diagnostic Vehicle PerformanceComponent PerformanceEnvironmental Component Testing Specification Vibration, Water Intrusion, Dust, Mechanical/Thermal Shock, High/Temp Endurance, ThermalHumidity.Efficiency 95%Output Voltage 250Vdc – 400VdcFull Operating Temperature range @ -40C to 70CAir CooledLevel 1 & 2 J-1772 compliantCAN Vehicle communication interface: Environmental & EMC Requirements: Reliability/Durability Requirements Assembly/Service/Packaging/LabelsThis presentation does not contain any proprietary, confidential, or otherwise restricted information22
Technical Summary – 2 Mode Hybrid TransmissionAHSF Information Two (2) EVT Modes Four (4) Fixed Gears Two (2) Planetary Gear Sets One (1) Compound – Dual Planets One (1) Single Planets Synchronous Shifting between Gears and Modes Two (2) Pumps One (1) Mechanical – Engine Driven One (1) ElectricFour (4) Wet Clutches Two (2) Brake Two (2) Rotating Damper Bypass Clutch for smooth engine start/stopThis presentation does not contain any proprietary, confidential, or otherwise restricted information23
RT PHEV Thermal System SummaryBehr America – Major Contributions–––––1D system simulation to size heat exchangers and pumpsCAD packaging and design of major thermal system componentsFabrication of all heat exchangersSourcing of coolant and A/C hose & tube assemblies, coolant control valvesFull system bench testing prior to vehicle installationRT – MiniVan Thermal System OverviewMajor Components Engine Cooling Battery Heating & Cooling Charging System Cooling Power Electronics CoolingThis presentation does not contain any proprietary, confidential, or otherwise restricted information24
RT – Fuel Economy TargetsBase RT FE cert (4750 ETW)Unadjusted City @ 20.60 Label 17 (MPG method)Unadjusted Hwy @ 34.15 Label 25 (MPG method)RT PHEV Targets (5500 ETW)Charge Depleting : FE CITY: Simulation results – 47.7 MPG 16.07kWh/100mi»»Utility Factors (SAE J 2841) based - CD & CS are combined and reported as onenumber; Fuel Energy & Electrical Energy reported separately (no MPGe).Vehicle kWh/100mi was calculated using a nominal charging system efficiency of88%.Charge SustainingUnadjusted Charge Sustaining City @ 30.90 Unadj; Label 24 (MPG method)Unadjusted Charge Sustaining Hwy @ 37.57 Unadj; Label 27 (MPG method)This presentation does not contain any proprietary, confidential, or otherwise restricted information25
E J 2841) based - CD & CS are combined and reported as onenumber; Fuel Energy & Electrical Energy reported separately (no MPGe).Vehicle kWh/100mi was calculated using a nominal charging system efficiency of88%.Charge SustainingUnadjusted Charge Sustaining City @ 30.90 Unadj; Label 24 (MPG method)Unadjusted Charge Sustaining Hwy @ 37.57 Unadj; Label 27 (MPG method)This presentation does not contain any proprietary, confidential, or otherwise restricted information25
Electric Motors 6.6 Kw Charger Plug In Hybrid Controls E- Motor Battery Hybrid Vehicle Transmission Thermal Systems 2-Mode Hybrid Transmission Technical Approach This presentation does not contain any proprietary, confidential, or otherwise restricted information 6 J1772
SONATA Hybrid & Plug-in Hybrid Hybrid SE Hybrid Limited Plug-in Hybrid Plug-in Hybrid Limited Power & Handling 193 net hp, 2.0L GDI 4-cylinder hybrid engine with 38 kW permanent magnet high-power density motor —— 202 net hp, 2.0L GDI 4-cylinder hybrid engine with 50 kW permanent magnet high-power density motor —— 6-speed automatic .
Hybrid. [19] Plug-in hybrids (PHEVs) Main Article: Plug-in hybrid The first generation Chevrolet Volt was a plug-in hybrid that could run up to 35 miles (56 km) in all-electric mode. A plug-in hybrid electric vehicle (PHEV), also known as a plug-in hybrid
Kia Niro 2018, 2019, 2020 Plug-In Hybrid 4409 Kia Niro EV 2019, 2020 Electric Drive Plug-In 4916 Jaguar I-Pace 2018, 2019, 2020 Electric Drive Plug-In 5886 Land Rover Range Rover 2020 Plug-In Hybrid 6125 Land Rover Range Rover Sport 2020 Plug-In Hybrid 7050 Lincoln Aviator PHEV 2020, 2021 Plug-in Hybrid 7150 .
Single Set Screw Termination U R Double Set Screw Termination U R Male Plug Female Plug Male Plug Female Plug 18D21-U* 18D29-U* 18D22-U* 18D31-U* Cable Size: 2/0 - 4/0 Max Ampacity: 400A Single Set Screw Termination U R Double Set Screw Termination U R Male Plug Female Plug Male Plug Female Plug 18D23-U* 18D32-U* 18D24-U* 18D33-U*
Designed for experience and built for connection, the European-styled Escape range includes ST-Line, Vignale and Ford's first-ever Plug-In Hybrid, available from late 2022. Plug-in Hybrid. Available from 2022, the Escape Plug-in Hybrid uses two power sources to get you there more efficiently. The Escape PHEV can travel up to 56km with zero emissions while, for longer journeys, power split technology recharges the hybrid battery as you drive.
Optima Hybrid (HEV) and Plug-In Hybrid (PHEV) feature Kia’s full parallel hybrid system, a cutting- edge design that allows both the gasoline engine and electric motor to simultaneously provide power directly to the wheels for optimum efficiency1 and responsive performance in a variety of road conditions.
Optima Hybrid (HEV) and Plug-in Hybrid (PHEV) feature Kia’s Full Parallel Hybrid system, a cutting-edge design that allows both the gasoline engine and electric motor to simultaneously provide power directly to the wheels for optimum efficiency1 and superb performance in a variety of road conditions.
Send comments (with copy to psa@ansi.org) to: Christina Earl, (315) 339-6937, cearl@esda.org TCIA (ASC A300) (Tree Care Industry Association) Revision BSR A300 (Part 3)-201x, Tree Care Operations - Tree, Shrub, and Other Woody Plant Management - Standard Practices (Supplemental Support Systems) (revision of ANSI A300 (Part 3)-2006)
