Performance Evaluation of Lower- Energy Energy Storage Alternatives for Full-Hybrid Vehicles

Transcription

1 Perfrmance Evaluatin f Lwer- Energy Energy Strage Alternatives fr Full-Hybrid Vehicles SAE 2014 Hybrid & Electric Vehicle Technlgies Sympsium La Jlla, Califrnia February 11-13, 2014 Jeff Gnder, Jn Csgrve and Ahmad Pesaran Natinal Renewable Energy Labratry (NREL) Transprtatin and Hydrgen Systems Center (THSC) Prject supprted by the DOE Vehicle Technlgies Office NREL/PR NREL is a natinal labratry f the U.S. Department f Energy, Office f Energy Efficiency and Renewable Energy, perated by the Alliance fr Sustainable Energy, LLC.

2 Mtivatin Hybrid electric vehicles (HEVs) are effective at reducing pervehicle fuel use Incremental cst remains a barrier t wider market penetratin Energy strage system (ESS) arguably the largest cntributr ESS cst reductins/perfrmance imprvements imprved vehicle-level cst vs. benefit Increase market demand and aggregate fuel savings LEESS cnsideratins Technical evaluatin can it d the jb? Ptential fr lwer cst with less energy? Ptential benefits frm alternative technlgy? Better life, better cld temperature perfrmance Prject Fcus 2

3 Related Backgrund Wrk: NREL Evaluatin fr GM f Replacing NiMH Batteries with Ultracapacitrs in the 42-V Saturn Vue BAS HEV Mtivatin: Ucap ptential fr superir cycle life, cld temperature perfrmance, and lng-term cst reductins Bench tested Ucaps and retrfitted vehicle t perate in 3 cnfiguratins Phts by Jeff Gnder and Jasn Lustbader, NREL Findings: 42V HEV with ultracapacitrs perfrmed at least as well as the stck cnfiguratin with a NiMH battery BAS = belt alternatr starter ( mild HEV) 3

4 Additinal Backgrund: NREL Analysis fr USABC f Full-HEV Fuel Savings Sensitivity t Energy Strage Size NREL perfrmed simulatins and analyzed test data in cnjunctin with an EES TT Wrkgrup Re-evaluating ESS targets established in the late 1990s / early 2000s Results suggested pwer-assist HEVs can still achieve high fuel savings with lwer energy and ptentially lwer-cst ESS see: Gnder, J.; Pesaran, A.; Hwell, D.; Tataria, H. Lwer- Energy Requirements fr Pwer-Assist HEV Energy Strage Systems Analysis and Ratinale. Prceedings f the 27 th Internatinal Battery Seminar and Exhibit; Mar 15-18, 2010, Frt Lauderdale, FL. USABC established targets and began supprting device develpers See: Open t any ESS technlgy (very high pwer batteries, electrchemical dublelayer capacitrs, r asymmetric supercapacitrs) USABC = United States Advanced Battery Cnsrtium EES TT = The FreedmCAR/USDRIVE Electrchemical Energy Strage Technical Team 4

5 Current Prject: Hardware Evaluatin f Ptential Full-HEV LEESS Devices Set up a reusable vehicle test platfrm using a 2012 Frd Fusin Hybrid Cperative research and develpment agreement (CRADA) with Frd t facilitate Secnd set f prductin Frd cntrl mdules t interface with LEESS cells Custm state estimatr sends instantaneus state f charge (SOC) and pwer capability infrmatin t vehicle cntrller Maintain stck perating capability (using prductin NiMH cells) Able t switch between peratin using the stck battery and using the LEESS device under test Prvides back-t-back perfrmance cmparisn Phts by Jhn Ireland, NREL Fusin test platfrm and tractin battery with Bussed Electrical Center (BEC), Battery Pack Sensr Mdule (BPSM), and Battery Energy Cntrl Mdule (BECM) 5

6 Bench Testing f First LEESS under Evaluatin JSR Micr prvided LIC mdules Asymmetric strage device with battery and ultracapacitr-type characteristics 3.8 V max/cell, and dubled vlumetric capacitance due t lithium dping Figure curtesy f JSR Micr Cnversin pack sizing # f Cells Nminal Vltage Ttal Energy (Wh) Stck Sany NiMH* ,370 8 JSR 192 F LIC Mdules ** *Based n fact sheet published by Idah Natinal Labratry (INL): **Assuming 175 V 350 V maximum in-vehicle perating windw 6

7 JSR LIC Pack Characterizatin Bench cycling at multiple temperatures Static capacity test Hybrid pulse pwer characterizatin (HPPC) US06 drive prfile Impedance 2 3x less than NiMH* 25 C, 8-Mdule HPPC Results Pht by Jhn Ireland, NREL *Based n calculatins frm INL fact sheet OCV = pen circuit vltage 7

8 US06 Stck Vehicle (NiMH) & LEESS (JSR LIC) Lab Cmparisn Discharging (assist) Charging (regenerative braking) Stck battery data curtesy f Argnne Natinal Labratry (ANL) chassis dynammeter testing US06 = aggressive drive cycle with high speeds and acceleratins 8

9 US06 Prfile Cmparisn: Stck Battery (in vehicle) vs. JSR Micr LIC (in lab) 9

10 LEESS Cntrl and Vehicle Interface: MABx, LIC State Estimatin, and Vehicle Cmmunicatin Cntrls fr LIC state estimatin, safety, etc. implemented via rapid cntrl prttyping with dspace MicrAutBx (MABx) Adaptive state estimatin mdel used t mnitr LEESS pack state and estimate pwer capabilities State estimatin and pwer capabilities were validated against bench test data frm LIC mdules underging US06 and HPPC cycles MABx interfaces with LEESS mdules and with the Frd hybrid cntrller ver the vehicle cntrller area netwrk (CAN) bus Simulink state estimatin mdel (abve), and LEESS installatin in the trunk space shwing the JSR LICs and MABx (Pht by Jn Csgrve, NREL) 10

11 In-Vehicle Cmparisn: 0 60 mph Acceleratins* Stck Battery (NiMH) & LEESS (JSR LIC) Pht by Petr Sindler, NREL * Run with extra mass f bth ESSs and at high altitude N significant difference fund between acceleratin times while in NiMH cnfiguratin vs. LEESS cnfiguratin 11

12 In-Vehicle Cmparisn: Dynammeter Testing Test Schedule Perfrmed standard drive cycles with vehicle in NiMH and LEESS cnfiguratins Test cycles included: FTP/UDDS HWFET US06 Cld (20 F) FTP Vehicle CAN traffic recrded using the MABx Dynammeter Facility Testing details CAN fuel rate calibrated t bag measurements fr cmparisns FTP/UDDS = Federal Test Prcedure/Urban Dynammeter Driving Schedule (city testing) HWFET = Highway Fuel Ecnmy Test Pht by Jn Csgrve, NREL 12

13 In-Vehicle Cmparisn: Dynammeter Testing Prductin NiMH vs. 3 LIC cnfiguratins Evaluated several LIC scenaris in additin t the prductin cnfiguratin LIC-High: Energy cnstrained nly by vehicle and device vltage limits LIC-Med: Artificially reduced upper vltage limit t cnstrain energy LIC-Lw: Further reduced upper vltage limit fr mst cnstrained evaluatin Vltage Levels During UDDS Testing Vltage (V) 13

14 In-Vehicle Dynammeter Testing: Fuel and Energy Use Cmparisns Small fuel use differences between the HEV cnfiguratins all shw significant savings cmpared t the nn-hybrid vehicle Als measure energy windw used by each ESS cnfiguratin fr each cycle Cumulative ESS Wh t vehicle Energy ut fr electric launch/assist Energy return frm charging/regen. Charge sustaining ver cycle (n net energy use) In-use Energy Windw defined by (max min) fr the particular cycle Ttal energy Energy windw actually used 14

15 In-Vehicle Dynammeter Testing: Cmparing NiMH and LIC-High Scenari Charging (regenerative braking) Discharging (assist) Spd[mph], Energy Prfile[Wh], Fuel[g/10] Wh UDDS Fuel Use and Energy Windw 120 Wh NiMH Case Speed NiMH Energy Prfile NiMH Case Fuel LIC Case Speed LIC Energy Prfile LIC Case Fuel time [sec] 15

16 In-Vehicle Dynammeter Testing: Cmparing NiMH and LIC-Lw Scenari Charging (regenerative braking) Discharging (assist) Spd[mph], Energy Prfile[Wh], Fuel[g/10] Wh UDDS Fuel Use and Energy Windw 60 Wh NiMH Case Speed NiMH Energy Prfile NiMH Case Fuel LIC Case Speed LIC Energy Prfile LIC Case Fuel time [sec] 16

17 In-Vehicle Dynammeter Testing: Cmparing NiMH and LIC-Lw Scenari Charging (regenerative braking) Discharging (assist) Spd[mph], Energy Prfile[Wh], Fuel[g/10] UDDS Fuel Use and Energy Windw NiMH Case Speed NiMH Energy Prfile NiMH Case Fuel LIC Case Speed LIC Energy Prfile LIC Case Fuel time [sec] 17

18 In-Vehicle Dynammeter Testing: Fuel Use and Energy Windw Observatins Cmparisn ver 75 F and 20 F City Test Cycles Negligible fuel cnsumptin difference frm significantly reduced energy windw 18

19 In-Vehicle Dynammeter Testing: Cmparing NiMH and LIC-Lw Scenari Charging (regenerative braking) Discharging (assist) Spd[mph], Energy Prfile[Wh], Fuel[g/10] HWFET Fuel Use and Energy Windw NiMH Case Speed NiMH Energy Prfile NiMH Case Fuel LIC Case Speed LIC Energy Prfile LIC Case Fuel 50 Wh 110 Wh time [sec] 19

20 In-Vehicle Dynammeter Testing: Fuel Use and Energy Windw Observatins Cmparisn ver Highway and High Speed/Acceleratin Test Cycles Small energy windw prvides level HWFET fuel cnsumptin and slightly increased US06 fuel cnsumptin 20

21 In-Vehicle Dynammeter Testing: Cmparing NiMH and LIC-Lw Scenari Charging (regenerative braking) Discharging (assist) Spd[mph], Energy Prfile[Wh], Fuel[g/10] US06 Fuel Use and Energy Windw NiMH Case Speed NiMH Energy Prfile NiMH Case Fuel LIC Case Speed LIC Energy Prfile LIC Case Fuel time [sec] 21

22 In-Vehicle Dynammeter Testing: Fuel Use and Energy Windw Observatins Cmparisn ver All Cycles Run t Date Significantly reduced energy windw resulted in negligible fuel cnsumptin difference n mst cycles and small increase n US06 test 22

23 Summary HEVs are effective at reducing per-vehicle fuel use ESS cst reductins/perfrmance imprvements imprved vehicle-level cst vs. benefit Increase market demand and aggregate fuel savings LEESS cnsideratins Technical evaluatin Rad testing shwed n differences in acceleratin times LIC cnfiguratins even with very small energy windws shwed negligible fuel cnsumptin difference t the prductin NiMH cnfiguratin fr many cycles, and slight increases n the US06 cycle nly LIC calibratin imprvements may imprve efficiency and drive quality As lng as engine can be started under wrst-case cnditins, cnsiderable ESS dwnsizing may minimally impact fuel savings Ptential t achieve cst savings Alternative technlgies may allw dwnsizing while still satisfying life, pwer, and cld temperature perfrmance requirements 23

24 Ptential Next Steps Wrap up JSR LIC testing 95 F SC03 fr air cnditining cmparisn case Very cld (e.g., -10 F -23 C) peratin Bench testing fllwed by in-vehicle evaluatin with additinal LEESS devices Next system will be ultracapacitr mdules Cnsider pssible changes if vehicle designed arund a LEESS device e.g., higher pwer mtr Cmbine evaluatin results with supplier cst estimates t refine business case assessment 24

25 Acknwledgments JSR Micr Prviding mdules fr evaluatin Related technical infrmatin and supprt Frd Mtr Cmpany CRADA facilitating vehicle cnversin U.S. Department f Energy Cst-shared supprt between tw Vehicle Technlgies Office activities Energy Strage (ES) Vehicle Systems Simulatin and Testing (VSST) USABC Cllabrated n precursr analysis t this effrt and established LEESS perfrmance targets fr pwer-assist HEVs Maxwell Technlgies Prviding duble-layer capacitrs as next system t test 25

26 Questins? Authr cntact: Jeff Gnder