James Francfort

U.S. Department of Energy Vehicle Technologies Program -- Advanced Vehicle Testing Activity -- Plug-in Hybrid Electric Vehicle Charging Infrastructure Review

Plug-in hybrid electric vehicles (PHEVs) are under evaluation by various stake holders to better understand their capability and potential benefits. PHEVs could allow users to significantly improve fuel economy over a standard HEV and in some cases, depending on daily driving requirements and vehicle design, have the ability to eliminate fuel consumption entirely for daily vehicle trips. The cost associated with providing charge infrastructure for PHEVs, along with the additional costs for the on-board power electronics and added battery requirements associated with PHEV technology will be a key factor in the success of PHEVs. This report analyzes the infrastructure requirements for PHEVs in single family residential, multi-family residential and commercial situations. Costs associated with this infrastructure are tabulated, providing an estimate of the infrastructure costs associated with PHEV deployment.

Hydrogen ICE Vehicle Testing Activities

The Advanced Vehicle Testing Activity teamed with Electric Transportation Applications and Arizona Public Service to develop and monitor the operations of the APS Alternative Fuel (Hydrogen) Pilot Plant. The Pilot Plant provides 100% hydrogen, and hydrogen and compressed natural gas (H/CNG)-blended fuels for the evaluation of hydrogen and H/CNG internal combustion engine (ICE) vehicles in controlled and fleet testing environments. Since June 2002, twenty hydrogen and H/CNG vehicles have accumulated 300,000 test miles and 5,700 fueling events. The AVTA is part of the Department of Energy’s FreedomCAR and Vehicle Technologies Program. These testing activities are managed by the Idaho National Laboratory. This paper discusses the Pilot Plant design and monitoring, and hydrogen ICE vehicle testing methods and results.

Hybrid Electric Vehicle Fleet and Baseline Performance Testing

The U.S. Department of Energy’s Advanced Vehicle Testing Activity (AVTA) conducts baseline performance and fleet testing of hybrid electric vehicles (HEV). To date, the AVTA has completed baseline performance testing on seven HEV models and accumulated 1.4 million fleet testing miles on 26 HEVs. The HEV models tested or in testing include: Toyota Gen I and Gen II Prius, and Highlander; Honda Insight, Civic and Accord; Chevrolet Silverado; Ford Escape; and Lexus RX 400h. The baseline performance testing includes dynamometer and closed track testing to document the HEV’s fuel economy (SAE J1634) and performance in a controlled environment. During fleet testing, two of each HEV model are driven to 160,000 miles per vehicle within 36 months, during which maintenance and repair events, and fuel use is recorded and used to compile life-cycle costs. At the conclusion of the 160,000 miles of fleet testing, the SAE J1634 tests are rerun and each HEV battery pack is tested. These AVTA testing activities are conducted by the Idaho National Laboratory, Electric Transportation Applications, and Exponent Failure Analysis Associates. This paper discusses the testing methods and results.

Cost Benefit Analysis Modeling Tool for Electric vs. ICE Airport Ground Support Equipment – Development and Results

This report documents efforts to develop a computer tool for modeling the economic payback for comparative airport ground support equipment (GSE) that are propelled by either electric motors or gasoline and diesel engines. The types of GSE modeled are pushback tractors, baggage tractors, and belt loaders. The GSE modeling tool includes an emissions module that estimates the amount of tailpipe emissions saved by replacing internal combustion engine GSE with electric GSE. This report contains modeling assumptions, methodology, a user’s manual, and modeling results. The model was developed based on the operations of two airlines at four United States airports.

Guidelines for the Establishment of a Model Neighborhood Electric Vehicle (NEV) Fleet

The U.S. Department of Energy’s Advanced Vehicle Testing Activity tests neighborhood electric vehicles (NEVs) in both track and fleet testing environments. NEVs, which are also known as low speed vehicles, are light-duty vehicles with top speeds of between 20 and 25 mph, and total gross vehicle weights of approximately 2,000 pounds or less. NEVs have been found to be very viable alternatives to internal combustion engine vehicles based on their low operating costs. However, special charging infrastructure is usually necessary for successful NEV fleet deployment. Maintenance requirements are also unique to NEVs, especially if flooded lead acid batteries are used as they have watering requirements that require training, personnel protection equipment, and adherence to maintenance schedules. This report provides guidelines for fleet managers to follow in order to successfully introduce and operate NEVs in fleet environments. This report is based on the NEV testing and operational experience of personnel from the Advanced Vehicle Testing Activity, Electric Transportation Applications, and the Idaho National Laboratory.

INL Fleet Vehicle Characterization Study for the U.S. Department of Navy

Battelle Energy Alliance, LLC, managing and operating contractor for the U.S. Department of Energy’s Idaho National Laboratory, is the lead laboratory for U.S. Department of Energy Advanced Vehicle Testing. Battelle Energy Alliance, LLC collected and evaluated data on federal fleet operations as part of the Advanced Vehicle Testing Activity’s Federal Fleet Vehicle Data Logging and Characterization Study. The Advanced Vehicle Testing Activity’s study seeks to collect and evaluate data to validate use of advanced plug-in electric vehicle (PEV) transportation. This report focuses on US Department of Navys fleet to identify daily operational characteristics of select vehicles and report findings on vehicle and mission characterizations to support the successful introduction of PEVs into the agency’s fleets. Individual observations of these selected vehicles provide the basis for recommendations related to electric vehicle adoption and whether a battery electric vehicle or plug-in hybrid electric vehicle (collectively referred to as PEVs) can fulfill the mission requirements.

Electric Ground Support Equipment Advanced Battery Technology Demonstration Project at the Ontario Airport

The intent of the electric Ground Support Equipment (eGSE) demonstration is to evaluate the day-to-day vehicle performance of electric baggage tractors using two advanced battery technologies to demonstrate possible replacements for the flooded lead-acid (FLA) batteries utilized throughout the industry. These advanced battery technologies have the potential to resolve barriers to the widespread adoption of eGSE deployment. Validation testing had not previously been performed within fleet operations to determine if the performance of current advanced batteries is sufficient to withstand the duty cycle of electric baggage tractors. This report summarizes the work performed and data accumulated during this demonstration in an effort to validate the capabilities of advanced battery technologies. This report summarizes the work performed and data accumulated during this demonstration in an effort to validate the capabilities of advanced battery technologies. The demonstration project also grew the relationship with Southwest Airlines (SWA), our demonstration partner at Ontario International Airport (ONT), located in Ontario, California. The results of this study have encouraged a proposal for a future demonstration project with SWA.

Vehicle to Electric Vehicle Supply Equipment Smart Grid Communications Interface Research and Testing Report

Plug-in electric vehicles (PEVs), including battery electric, plug-in hybrid electric, and extended range electric vehicles, are under evaluation by the U.S. Department of Energys Advanced Vehicle Testing Activity (AVTA) and other various stakeholders to better understand their capability and potential petroleum reduction benefits. PEVs could allow users to significantly improve fuel economy over a standard hybrid electric vehicles, and in some cases, depending on daily driving requirements and vehicle design, PEVs may have the ability to eliminate petroleum consumption entirely for daily vehicle trips. The AVTA is working jointly with the Society of Automotive Engineers (SAE) to assist in the further development of standards necessary for the advancement of PEVs. This report analyzes different methods and available hardware for advanced communications between the electric vehicle supply equipment (EVSE) and the PEV; particularly Power Line Devices and their physical layer. Results of this study are not conclusive, but add to the collective knowledge base in this area to help define further testing that will be necessary for the development of the final recommended SAE communications standard. The Idaho National Laboratory and the Electric Transportation Applications conduct the AVTA for the United States Department of Energys Vehicle Technologies Program.

Advanced Vehicle Testing Activity: Dodge Ram Wagon Van -- Hydrogen/CNG Operations Summary

Over the past two years, Arizona Public Service, a subsidiary of Pinnacle West Capital Corporation, in cooperation with the U.S. Department of Energy’s Advanced Vehicle Testing Activity, tested four gaseous fuel vehicles as part of its alternative fueled vehicle fleet. One vehicle, a Dodge Ram Wagon Van, operated initially using compressed natural gas (CNG) and later a blend of CNG and hydrogen. Of the other three vehicles, one was fueled with pure hydrogen and two were fueled with a blend of CNG and hydrogen. The three blended-fuel vehicles were originally equipped with either factory CNG engines or factory gasoline engines that were converted to run CNG fuel. The vehicles were variously modified to operate on blended fuel and were tested using 15 to 50% blends of hydrogen (by volume). The pure-hydrogen-fueled vehicle was converted from gasoline fuel to operate on 100% hydrogen. All vehicles were fueled from the Arizona Public Service’s Alternative Fuel Pilot Plant, which was developed to dispense gaseous fuels, including CNG, blends of CNG and hydrogen, and pure hydrogen with up to 99.9999% purity. The primary objective of the test was to evaluate the safety and reliability of operating vehicles on hydrogen and blended hydrogen fuel, and the interface between the vehicles and the hydrogen fueling infrastructure. A secondary objective was to quantify vehicle emissions, cost, and performance. Over a total of 40,000 fleet test miles, no safety issues were found. Also, significant reductions in emissions were achieved by adding hydrogen to the fuel. This report presents results of 22,816 miles of testing for the Dodge Ram Wagon Van, operating on CNG fuel, and a blended fuel of 15% hydrogen–85% CNG.