Lithium-Ion 6T Battery Technology Field Testing in Commercial Trucks. Jasna Tomic, CALSTART Laurence Toomey, US Army RDECOM-TARDEC
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1 Lithium-Ion 6T Battery Technology Field Testing in Commercial Trucks Jasna Tomic, CALSTART Laurence Toomey, US Army RDECOM-TARDEC 25 August 2014
2 Agenda Introduction Commercial Requirements Military Requirements Battery and Vehicle Selection Test Vehicles and Regions Test Plan Results Installation Performance Results Vehicle and Battery Issues Conclusions & Future Work 25 August
3 Introduction Collaboration between TARDEC and CALSTART Develop Li-Ion 6T form factor (12V and 24V) for ultimate goal of dual-use in military and commercial sector Demonstrate feasibility in real-world Class 8 commercial truck Identify ideal vehicle applications for future implementations 25 August
4 Introduction Commercial Requirements: Reliable starting Environmentally friendly Lifecycle up to useful vehicle lifetime (8-10 years) Military Requirements: High power and energy density with long lifecycle Reduced maintenance and replacement costs Overlap: Capability to support start/stop, engine-off ops, hotel loads/silent watch Weight reduction 25 August
5 Battery and Vehicle Selection Battery Technologies Cylindrical Li-Ion Iron Phosphate Prismatic Li-Ion Iron Phosphate NiCoAl Li-Ion Starter Application High power for cranking Group 31 Battery: 6T Battery: 239.7mm 750A 170.7mm 330.2mm 230mm 1100A 269mm 286mm 25 August
6 Battery and Vehicle Selection Test Vehicles and Regions Commercial fleet with over 20,000 vehicles in North America Hot region: San Bernardino, CA & Cold region: Henderson, CO Vehicle Characteristics Description Chassis Manufacturer / Model / Model Year Kenworth / T800B / 2006 & 2007 Engine Manufacturer / Model Cummins / ISX 450 L6, 14.9L Power Rating 450 hp Torque Rating 1,650 rpm Drive Line 4x2 Transmission Eaton-Fuller 10 speed FR15210B GVWR 34,700 lbs Alternator PACCAR D P Voltage / Current 12V / 130A 25 August
7 Test Plan 6 vehicle deployments - 3 per region 2 vehicle tests cut short due to vehicle/battery failures 25 August
8 Test Plan Data collection equipment instrumented via J1939 port Vehicle and battery parameters sampled at 1Hz and 10Hz frequency Vehicle Parameters Units Time Seconds Accelerator Pedal Position % Drivers Demand Engine Percent Torque % Actual Engine Percent Torque % Engine Speed RPM Engine Demand Percent Torque % Wheel Based Vehicle Speed km/h Engine Fuel Rate l/h Ambient Air Temperature C GPS Latitude - GPS Longitude - Battery Parameters Current Voltage Units State of Charge % Temperature C Error Messages - Alternator Current A V A 25 August
9 Results Battery Installation 3 x 12V 6T replace 4 x 12V G31 Hold-down hardware & cabling 25 August
10 Results Data Collection Equipment Installation Data logger, cell modem Antenna, GPS transceiver BMS CAN HI/LO cable 25 August
11 Results Performance Results 6 trucks in 2 locations August 2013 thru April 2014 Metric Recorded Days Engine Time Cranking Events Distance Travelled Fuel Consumed Ave Fuel Economy Ave Driving Speed Min. Ambient Temp Max. Ambient Temp Demo Total 328 days 2,195 hours 8,699 times 88,476 miles 14,248 gallons 6.2 MPG 39.0 MPH C (February 5 ) CO C (Sept 9) 2013 CA 25 August
12 Results California Performance Results Supplier A Supplier B Recorded Days Cranking Events Distanc e Fuel Econ. MPG Min T, C Max T, C , Ave 26/day Ave 22/day Supplier C , Ave 30/day 25 August
13 Results Colorado Performance Results Supplier A Recorded Days Cranking Events Distance Fuel Econ MPG Min T, C Max T, C Ave 16/day Supplier B Ave 27/day Supplier C Ave 25/day 25 August
14 Results SOC and Heater Usage Low SOC variation for Supplier A in Colorado: Rapid cell heating by Supplier A in Colorado: 25 August
15 Results SOC parasitic drawdown SOC drawdown for Supplier C in California: 25 August
16 Results Vehicle and Battery Issues Data communication issues (CAN HI/LO reversal) Maintenance unfamiliarity with Lithium-Ion and BMS protocols No battery malfunctioning events 25 August
17 Conclusions & Future Work Successful integration on Class 8 commercial tractors 6T format feasibly fits into commercial trucks w/modifications 12V 6T Li-Ion battery from 3 manufacturers adequately start vehicle w/o issue Each truck starts per day Performed in cold and hot climate, -26C to +46C High costs and limited return on investment in starting application Commercial trucks users remain interested in advanced Li-ion batteries 25 August
18 Conclusions & Future Work Target trucks using fuel to power accessories and/or applications with extended idle 1) Class 8 starter battery with high accessory usage and/or APU 2) Class 8 sleeper cab with hotel loads 3) epto or engine start/stop 4) Hydraulic-electric lift-gates 25 August
19 Acknowledgment Funding for this was provided by U.S. Army Tank and Automotive Research, Development and Engineering Center Co-authors Ted Bloch-Rubin and Jean-Baptiste Gallo, CALSTART 25 August
20 Questions Jasna Tomic, 25 August
21 2014 HTUF Annual Meeting 2014 HTUF Annual Meeting Sep 23-24, Day Event with WG s and Ride & Drive 25 August
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