John P. Rugh

Technology Improvement Pathways to Cost-effective Vehicle Electrification

Electrifying transportation can reduce or eliminate dependence on foreign fuels, emission of green house gases, and emission of pollutants. One challenge is finding a pathway for vehicles that gains wide market acceptance to achieve a meaningful benefit. This paper evaluates several approaches aimed at making plug-in electric vehicles (EV) and plug-in hybrid electric vehicles (PHEVs) cost-effective including opportunity charging, replacing the battery over the vehicle life, improving battery life, reducing battery cost, and providing electric power directly to the vehicle during a portion of its travel. Many combinations of PHEV electric range and battery power are included. For each case, the model accounts for battery cycle life and the national distribution of driving distances to size the battery optimally. Using the current estimates of battery life and cost, only the dynamically plugged-in pathway was cost-effective to the consumer. Significant improvements in battery life and battery cost also made PHEVs more cost-effective than todays hybrid electric vehicles (HEVs) and conventional internal combustion engine vehicles (CVs).

Reduction in Vehicle Temperatures and Fuel Use from Cabin Ventilation, Solar-Reflective Paint, and a New Solar-Reflective Glazing

An analysis to determine the impact of reducing the thermal load on a vehicle using solar-reflective paint and glazing.

Predicting human thermal comfort in a transient nonuniform thermal environment

The National Renewable Energy Laboratory has developed a suite of thermal comfort tools to assist in the development of smaller and more efficient climate control systems in automobiles. These tools, which include a 126-segment sweating manikin, a finite element physiological model of the human body, and a psychological model based on human testing, are designed to predict human thermal comfort in transient, nonuniform thermal environments, such as automobiles. The manikin measures the heat loss from the human body in the vehicle environment and sends the heat flux from each segment to the physiological model. The physiological model predicts the body’s response to the environment, determines 126-segment skin temperatures, sweat rate, and breathing rate, and transmits the data to the manikin. The psychological model uses temperature data from the physiological model to predict the local and global thermal comfort as a function of local skin and core temperatures and their rates of change. Results of initial integration testing show the thermal response of a manikin segment to transient environmental conditions.

Effect of Solar Reflective Glazing on Ford Explorer Climate Control, Fuel Economy, and Emissions

The energy used to air condition an automobile has a significant effect on vehicle fuel economy and tailpipe emissions. If a small reduction in energy use can be applied to many vehicles, the impact on national fuel consumption could be significant. The SCO3 is a new emissions test conducted with the air conditioner (A/C) operating that is part of the Supplemental Federal Test Procedure (SFTP). With the 100% phase-in of the SFTP in 2004 for passenger cars and light light-duty trucks, there is additional motivation to reduce the size of the A/C system. The U.S. Department of Energy’s National Renewable Energy Laboratory (NREL) is investigating ways to reduce the amount of energy consumed for automobile climate control. If the peak soak temperature in an automobile can be reduced, the power consumed by the air conditioner may be decreased while passenger comfort is maintained or enhanced. Solar reflective glass is one way to reduce the peak soak temperature. NREL and PPG Industries conducted a test program with Sungate laminated solar reflective glass installed in a Ford Explorer to quantify improvements in fuel economy and reductions in tailpipe emissions. Test results showed a dramatic reduction in interior and glass temperatures. After the A/C system and its effect on the passenger compartment were modeled to assess the potential reduction in compressor power, the vehicle performance was predicted.

Use of a Thermal Manikin to Evaluate Human Thermoregulatory Responses in Transient, Non-Uniform, Thermal Environments

People who wear protective uniforms that inhibit evaporation of sweat can experience reduced productivity and even health risks when their bodies cannot cool themselves. This paper describes a new sweating manikin and a numerical model of the human thermoregulatory system that evaluates the thermal response of an individual to transient, non-uniform thermal environments. The physiological model of the human thermoregulatory system controls a thermal manikin, resulting in surface temperature distributions representative of the human body. For example, surface temperatures of the extremities are cooler than those of the torso and head. The manikin contains batteries, a water reservoir, and wireless communications and controls that enable it to operate as long as 2 hours without external connections. The manikin has 120 separately controlled heating and sweating zones that result in high resolution for surface temperature, heat flux, and sweating control. The physiological finite element model uses approximately 40,000 solid thermal and blood network elements to represent the human body. The manikin and physiological model demonstrate their value in evaluating the thermoregulatory response of a person in a protective uniform. They can also be used to evaluate the effectiveness of personal cooling systems.

Integrated Numerical Modeling Process for Evaluating Automobile Climate Control Systems

The air-conditioning (A/C) system compressor load can significantly impact the fuel economy and tailpipe emissions of conventional and hybrid electric automobiles. With the increasing emphasis on fuel economy, it is clear that the A/C compressor load needs to be reduced. In order to accomplish this goal, more efficient climate control delivery systems and reduced peak soak temperatures will be necessary to reduce the impact of vehicle A/C systems on fuel economy and tailpipe emissions. Good analytical techniques are important in identifying promising concepts. The goal at the U.S. Department of Energy’s National Renewable Energy Laboratory (NREL) is to assess thermal comfort, fuel economy, and emissions by using an integrated modeling approach composed of CAD, computational fluid dynamics (CFD), thermal comfort, and vehicle simulation tools. This paper presents NREL’s vehicle integrated modeling process.

Effect of Solar-Reflective Glazing on Fuel Economy, Tailpipe Emissions, and Thermal Comfort

Current air-conditioning systems can reduce the fuel economy of high fuel-economy vehicles by about 50% and reduce the fuel economy of today’s mid-sized vehicles by more than 20% while increasing NOx by nearly 80% and CO by 70%. Automotive glazing has a significant impact on the peak and steady-state cooling loads of the vehicle. Glazing that reflects the infrared portion of the solar spectrum can reduce interior temperatures by 9°C and reject more than 500 W while the vehicle is parked. Such a windshield can improve the fuel economy of a compact car by about 0.3 km/L (0.7 mpg) over the SC03 drive cycle if the airconditioning system is appropriately down-sized.

The Impact of Metal-free Solar Reflective Film on Vehicle Climate Control

The air-conditioning system can significantly impact the fuel economy and tailpipe emissions of automobiles. If the peak soak temperature of the passenger compartment can be reduced, the air-conditioner compressor can potentially be downsized while maintaining human thermal comfort. Solar reflective film is one way to reduce the peak soak temperature by reducing the solar heat gain into the passenger compartment. A 3M non-metallic solar reflective film (SRF) was tested in two minivans and two sport utility vehicles (SUV). The peak soak temperature was reduced resulting in a quicker cooldown. Using these data, a reduction in air-conditioner size was estimated and the fuel economy and tailpipe emissions were predicted.

Using a Sweating Manikin, Controlled by a Human Physiological Model, to Evaluate Liquid Cooling Garments

This paper discusses the use of NRELs Advanced Automotive Manikin (ADAM) for evaluating NASAs liquid cooling garments for space suits.

Climate Control Load Reduction Strategies for Electric Drive Vehicles in Warm Weather

Passenger compartment climate control is one of the largest auxiliary loads on a vehicle. Like conventional vehicles, electric vehicles (EVs) require climate control to maintain occupant comfort and safety, but cabin heating and air conditioning have a negative impact on driving range for all-electric vehicles. Range reduction caused by climate control and other factors is a barrier to widespread adoption of EVs. Reducing the thermal loads on the climate control system will extend driving range, thereby reducing consumer range anxiety and increasing the market penetration of EVs. Researchers at the National Renewable Energy Laboratory have investigated strategies for vehicle climate control load reduction, with special attention toward EVs. Outdoor vehicle thermal testing was conducted on two 2012 Ford Focus Electric vehicles to evaluate thermal management strategies for warm weather, including solar load reduction and cabin pre-ventilation. An advanced thermal test manikin was used to assess a zonal approach to climate control. In addition, vehicle thermal analysis was used to support testing by exploring thermal load reduction strategies, evaluating occupant thermal comfort, and calculating EV range impacts. Through stationary cooling tests and vehicle simulations, a zonal cooling configuration demonstrated range improvement of 6%-15%, depending on the drive cycle. A combined cooling configuration that incorporated thermal load reduction and zonal cooling strategies showed up to 33% improvement in EV range.