Eric Wood

Comparison of Plug-In Hybrid Electric Vehicle Battery Life Across Geographies and Drive Cycles

In a laboratory environment, it is cost prohibitive to run automotive battery aging experiments across a wide range of possible ambient environment, drive cycle and charging scenarios. Since worst-case scenarios drive the conservative sizing of electric-drive vehicle batteries, it is useful to understand how and why those scenarios arise and what design or control actions might be taken to mitigate them. In an effort to explore this problem, this paper applies a semi-empirical life model of the graphite/nickel-cobalt-aluminum lithium-ion chemistry to investigate impacts of geographic environments under storage and simplified cycling conditions. The model is then applied to analyze complex cycling conditions, using battery charge/discharge profiles generated from simulations of PHEV10 and PHEV40 vehicles across 782 single-day driving cycles taken from Texas travel survey data.

Accounting for the Variation of Driver Aggression in the Simulation of Conventional and Advanced Vehicles

Hybrid electric vehicles, plug-in hybrid electric vehicles, and battery electric vehicles offer the potential to reduce both oil imports and greenhouse gases, as well as to offer a financial benefit to the driver. However, assessing these potential benefits is complicated by several factors, including the driving habits of the operator. We focus on driver aggression, i.e., the level of acceleration and velocity characteristic of travel, to (1) assess its variation within large, real-world drive datasets, (2) quantify its effect on both vehicle efficiency and economics for multiple vehicle types, (3) compare these results to those of standard drive cycles commonly used in the industry, and (4) create a representative drive cycle for future analyses where standard drive cycles are lacking.

Modular approach for continuous cell-level balancing to improve performance of large battery packs

Energy storage systems require battery cell balancing circuits to avoid divergence of cell state of charge (SOC). A modular approach based on distributed continuous cell-level control is presented that extends the balancing function to higher level pack performance objectives such as improving power capability and increasing pack lifetime. This is achieved by adding DC-DC converters in parallel with cells and using state estimation and control to autonomously bias individual cell SOC and SOC range, forcing healthier cells to be cycled deeper than weaker cells. The result is a pack with improved degradation characteristics and extended lifetime. The modular architecture and control concepts are developed and hardware results are demonstrated for a 91.2 Wh battery pack consisting of four series li-ion battery cells and four dual active bridge (DAB) bypass DC-DC converters.

FASTSim: A Model to Estimate Vehicle Efficiency, Cost and Performance

The Future Automotive Systems Technology Simulator (FASTSim) is a high-level advanced vehicle powertrain systems analysis tool supported by the U.S. Department of Energy’s Vehicle Technologies Office. FASTSim provides a quick and simple approach to compare powertrains and estimate the impact of technology improvements on light- and heavy-duty vehicle efficiency, performance, cost, and battery batches of real-world drive cycles. FASTSim’s calculation framework and balance among detail, accuracy, and speed enable it to simulate thousands of driven miles in minutes. The key components and vehicle outputs have been validated by comparing the model outputs to test data for many different vehicles to provide confidence in the results. A graphical user interface makes FASTSim easy and efficient to use. FASTSim is freely available for download from the National Renewable Energy Laboratory’s website (see www.nrel.gov/fastsim).

A Second Life for Electric Vehicle Batteries: Answering Questions on Battery Degradation and Value

Battery second use – putting used plug-in electric vehicle (PEV) batteries into secondary service following their automotive tenure – has been proposed as a means to decrease the cost of PEVs while providing low cost energy storage to other fields (e.g. electric utility markets). To understand the value of used automotive batteries, however, we must first answer several key questions related to National Renewable Energy Laboratory (NREL) has developed a methodology and the requisite tools to answer these questions, including NREL’s Battery Lifetime Simulation Tool (BLAST). Herein we introduce these methods and tools, and demonstrate their application. We have found that capacity fade from automotive use has a much larger impact on second use value than resistance growth. Where capacity loss is driven by calendar effects more than cycling effects, average battery temperature during automotive service – which is often driven by climate – is found to be the single factor with the largest effect on remaining value. Installing hardware and software capabilities onboard the vehicle that can both infer remaining battery capacity from in-situ measurements, as well as track average battery temperature over time, will thereby facilitate the second use of automotive batteries.

Contribution of Road Grade to the Energy Use of Modern Automobiles Across Large Datasets of Real-World Drive Cycles

Understanding the real-world power demand of modern automobiles is of critical importance to engineers using modeling and simulation to inform the intelligent design of increasingly efficient powertrains. Increased use of global positioning system (GPS) devices has made large scale data collection of vehicle speed (and associated power demand) a reality. While the availability of real-world GPS data has improved the industrys understanding of in-use vehicle power demand, relatively little attention has been paid to the incremental power requirements imposed by road grade. This analysis quantifies the incremental efficiency impacts of real-world road grade by appending high fidelity elevation profiles to GPS speed traces and performing a large simulation study. Employing a large real-world dataset from the National Renewable Energy Laboratorys Transportation Secure Data Center, vehicle powertrain simulations are performed with and without road grade under five vehicle models. Aggregate results of this study suggest that road grade could be responsible for 1% to 3% of fuel use in light-duty automobiles.

Identifying and Overcoming Critical Barriers to Widespread Second Use of PEV Batteries

Both the market penetration of plug-in electric vehicles (PEVs) and deployment of grid-connected energy storage systems are presently restricted by the high cost of batteries. Battery second use (B2U) strategies--in which a single battery first serves an automotive application, then is redeployed into a secondary market--could help address both issues by reducing battery costs to the primary (automotive) and secondary (electricity grid) users. This study investigates the feasibility of and major barriers to the second use of lithium-ion PEV batteries by posing and answering the following critical B2U questions: 1. When will used automotive batteries become available, and how healthy will they be? 2. What is required to repurpose used automotive batteries, and how much will it cost? 3. How will repurposed automotive batteries be used, how long will they last, and what is their value? Advanced analysis techniques are employed that consider the electrical, thermal, and degradation response of batteries in both the primary (automotive) and secondary service periods. Second use applications are treated in detail, addressing operational requirements, economic value, and market potential. The study concludes that B2U is viable and could provide considerable societal benefits due to the large possible supply of repurposed automotive batteries and substantialmorexa0» remaining battery life following automotive service. However, the only identified secondary market large enough to consume the supply of these batteries (utility peaker plant replacement) is expected to be a low margin market, and thus B2U is not expected to affect the upfront cost of PEVs.«xa0less

Will Your Battery Survive a World With Fast Chargers

Fast charging is attractive to battery electric vehicle (BEV) drivers for its ability to enable long-distance travel and to quickly recharge depleted batteries on short notice. However, such aggressive charging and the sustained vehicle operation that results could lead to excessive battery temperatures and degradation. Properly assessing the consequences of fast charging requires accounting for disparate cycling, heating, and aging of individual cells in large BEV packs when subjected to realistic travel patterns, usage of fast chargers, and climates over long durations (i.e., years). The U.S. Department of Energys Vehicle Technologies Office has supported the National Renewable Energy Laboratorys development of BLAST-V-the Battery Lifetime Analysis and Simulation Tool for Vehicles-to create a tool capable of accounting for all of these factors. We present on the findings of applying this tool to realistic fast charge scenarios. The effects of different travel patterns, climates, battery sizes, battery thermal management systems, and other factors on battery performance and degradation are presented. We find that the impact of realistic fast charging on battery degradation is minimal for most drivers, due to the low frequency of use. However, in the absence of active battery cooling systems, a drivers desired utilization of a BEV and fast charging infrastructure can result in unsafe peak battery temperatures. We find that active battery cooling systems can control peak battery temperatures to safe limits while allowing the desired use of the vehicle.

Connectivity-Enhanced Route Selection and Adaptive Control for the Chevrolet Volt

The National Renewable Energy Laboratory and General Motors evaluated connectivity-enabled efficiency enhancements for the Chevrolet Volt. A high-level model was developed to predict vehicle fuel and electricity consumption based on driving characteristics and vehicle state inputs. These techniques were leveraged to optimize energy efficiency via green routing and intelligent control mode scheduling, which were evaluated using prospective driving routes between tens of thousands of real-world origin/destination pairs. The overall energy savings potential of green routing and intelligent mode scheduling was estimated at 5% and 3%, respectively. Furthermore, these represent substantial opportunities considering that they only require software adjustments to implement.

Simulated Real-World Energy Impacts of a Thermally Sensitive Powertrain Considering Viscous Losses and Enrichment

It is widely understood that cold ambient temperatures increase vehicle fuel consumption due to heat transfer losses, increased friction (increased viscosity lubricants), and enrichment strategies (accelerated catalyst heating). However, relatively little effort has been dedicated to thoroughly quantifying these impacts across a large set of real world drive cycle data and ambient conditions. This work leverages experimental dynamometer vehicle data collected under various drive cycles and ambient conditions to develop a simplified modeling framework for quantifying thermal effects on vehicle energy consumption. These models are applied over a wide array of real-world usage profiles and typical meteorological data to develop estimates of in-use fuel economy. The paper concludes with a discussion of how this integrated testing/modeling approach may be applied to quantify real-world, off-cycle fuel economy benefits of various technologies.