Larry Eugene Seiber

Evaluation of the 2010 Toyota Prius Hybrid Synergy Drive System

Subsystems of the 2010 Toyota Prius hybrid electric vehicle (HEV) were studied and tested as part of an intensive benchmarking effort carried out to produce detailed information concerning the current state of nondomestic alternative vehicle technologies. Feedback provided by benchmarking efforts is particularly useful to partners of the Vehicle Technologies collaborative research program as it is essential in establishing reasonable yet challenging programmatic goals which facilitate development of competitive technologies. The competitive nature set forth by the Vehicle Technologies Program (VTP) not only promotes energy independence and economic stability, it also advocates the advancement of alternative vehicle technologies in an overall global perspective. These technologies greatly facilitate the potential to reduce dependency on depleting natural resources and mitigate harmful impacts of transportation upon the environment.

A novel wireless power transfer for in-motion EV/PHEV charging

Wireless power transfer (WPT) is a convenient, safe, and autonomous means for electric and plug-in hybrid electric vehicle charging that has seen rapid growth in recent years for stationary applications. WPT does not require bulky contacts, plugs, and wires, is not affected by dirt or weather conditions, and is as efficient as conventional charging systems. When applied in-motion, WPT additionally relives range anxiety, adds further convenience, reduces battery size, and may help increase the battery life through charge sustaining approach. This study summarizes some of the recent activities of Oak Ridge National Laboratory (ORNL) in WPT charging of EV and PHEVs inmotion. Laboratory experimental results that highlight the wireless transfer of power to a moving receiver coil as it passes a pair of transmit coils and investigation of results of insertion loss due to roadway surfacing materials. Some of the experimental lessons learned are also included in this study.

Demonstrating Dynamic Wireless Charging of an Electric Vehicle: The Benefit of Electrochemical Capacitor Smoothing

The wireless charging of an electric vehicle (EV) while it is in motion presents challenges in terms of low-latency communications for roadway coil excitation sequencing and maintenance of lateral alignment, plus the need for power-flow smoothing. This article summarizes the experimental results on power smoothing of in-motion wireless EV charging performed at the Oak Ridge National Laboratory (ORNL) using various combinations of electrochemical capacitors at the grid side and in the vehicle. Electrochemical capacitors of the symmetric carbon-carbon type from Maxwell Technologies comprised the in-vehicle smoothing of wireless charging current to the EV battery pack. Electro Standards Laboratories (ESL) fabricated the passive and active parallel lithium-capacitor (LiC) unit used to smooth the grid-side power. The power pulsation reduction was 81% on the grid by the LiC, and 84% on the vehicle for both the LiC and the carbon ultracapacitors (UCs).

Evaluation of the 2007 Toyota Camry Hybrid Synergy Drive System

The U.S. Department of Energy (DOE) and American automotive manufacturers General Motors, Ford, and DaimlerChrysler began a five-year, cost-shared partnership in 1993. Currently, hybrid electric vehicle (HEV) research and development is conducted by DOE through its FreedomCAR and Vehicle Technologies (FCVT) program. The mission of the FCVT program is to develop more energy efficient and environmentally friendly highway transportation technologies. Program activities include research, development, demonstration, testing, technology validation, and technology transfer. These activities are aimed at developing technologies that can be domestically produced in a clean and cost-competitive manner. Under the FCVT program, support is provided through a three-phase approach [1] which is intended to: • Identify overall propulsion and vehicle-related needs by analyzing programmatic goals and reviewing industry’s recommendations and requirements, then develop the appropriate technical targets for systems, subsystems, and component research and development activities; • Develop and validate individual subsystems and components, including electric motors, emission control devices, battery systems, power electronics, accessories, and devices to reduce parasitic losses; and • Determine how well the components and subassemblies work together in a vehicle environment or as a complete propulsion system and whether the efficiency and performance targets at the vehicle level have been achieved. The research performed in this area will help remove technical and cost barriers to enable technology for use in such advanced vehicles as hybrid electric, plug-in hybrid electric, electric, and fuel-cell-powered vehicles.

Oak Ridge National Laboratory Wireless Power Transfer Development for Sustainable Campus Initiative

Wireless power transfer (WPT) is a convenient, safe, and autonomous means for electric and plug-in hybrid electric vehicle charging that has seen rapid growth in recent years for stationary applications. WPT does not require bulky contacts, plugs, and wires, is not affected by dirt or weather conditions, and is as efficient as conventional charging systems. This study summarizes some of the recent Sustainable Campus Initiative activities of Oak Ridge National Laboratory (ORNL) in WPT charging of an on-campus vehicle (a Toyota Prius plug-in hybrid electric vehicle). Laboratory development of the WPT coils, high-frequency power inverter, and overall systems integration are discussed. Results cover the coil performance testing at different operating frequencies, airgaps, and misalignments. Some of the experimental results of insertion loss due to roadway surfacing materials in the air-gap are presented. Experimental lessons learned are also covered in this study.

Evaluation of the 2008 Lexus LS 600H Hybrid Synergy Drive System

Subsystems of the 2008 Lexus 600h hybrid electric vehicle (HEV) were studied and tested as part of an intensive benchmarking effort carried out to produce detailed information concerning the current state of nondomestic alternative vehicle technologies. Feedback provided by benchmarking efforts is particularly useful to partners of the Vehicle Technologies collaborative research program as it is essential in establishing reasonable yet challenging programmatic goals which facilitate development of competitive technologies. The competitive nature set forth by the Vehicle Technologies program not only promotes energy independence and economic stability, it also advocates the advancement of alternative vehicle technologies in an overall global perspective. These technologies greatly facilitate the potential to reduce dependency on depleting natural resources and mitigate harmful impacts of transportation upon the environment.

Electronic power conversion system for an advanced mobile generator set

The electronic power conversion system and control for an advanced mobile generator set is described. The military generator set uses an internal combustion diesel engine to drive a radial-gap permanent magnet alternator at variable speed. The speed of the engine is determined from a user selectable interface that for a given load and ambient thermal conditions controls the engine to run at its most efficient operating point. It is also possible to control the engine to run where it is most audibly quiet, at its least-polluting operating point, or at its most reliable, stiffest point such that it is less sensitive to load transients. The variable frequency, variable voltage produced by the permanent magnet alternator is diode-rectified to DC voltage, and an inverter is used to produce selectable frequency, controllable AC voltage. The power conversion system also incorporates a bi-directional DC-DC converter that can charge 24 V batteries that are used to start the IC engine and to power auxiliary loads. The bi-directional converter can also draw power from the batteries to help maintain the DC link during severe load transients. The design of this new generator set offers additional flexibility by being lighter, smaller, and more fuel efficient than a conventional fixed-speed gen-set.

A high-power wireless charging system development and integration for a Toyota RAV4 electric vehicle

Several wireless charging methods are under development or available as an aftermarket option in the light-duty automotive market. However, there are not many studies detailing the vehicle integrations, particularly a fully integrated vehicle application. This paper presents the development, implementation, and vehicle integration of a high-power (>10 kW) wireless power transfer (WPT)-based electric vehicle (EV) charging system for a Toyota RAV4 vehicle. The power stages of the system are introduced with the design specifications and control systems including the active front-end rectifier with power factor correction (PFC), high frequency power inverter, high frequency isolation transformer, coupling coils, vehicle side full-bridge rectifier and filter, and the vehicle battery. The operating principles of the overall wireless charging system as well as the control system are presented. The physical limitations of the system are also defined that would prevent the system from operating at higher levels. The system performance is shown for two cases including unmatched (interoperable) and matched coils. The experiments are carried out using the integrated vehicle and the results are obtained to demonstrate the system performance including the stage-by-stage efficiencies with matched and interoperable primary and secondary coils.

Calorimeter evaluation of inverter grade metalized film capacitor ESR

The capacitor industry requires fast and accurate characterization of component equivalent series resistance (ESR) and capacitance (C). In a manufacturing setting the measurements must be very fast, repeatable and high quality for use in process control, data collection and monitoring, plus for printing on the component SKU label. The fastest characterization testing is done electronically using pulse techniques and these must provide accurate assessment of the true parameter values. In this work a calorimeter method was developed to corroborate ESR values obtained using a recently developed electronic ESR characterization method at ORNL. Calorimeter measurements are very slow, tedious and subject to error if chamber inlet air is not properly conditioned. It was found that the provisional coplanar bus plate used for mounting a power ring high current capacitor introduced frequency dependence in ESR results that electronic measurement techniques did not incur. The calorimeter method lends itself well to parameter characterization under real world application conditions at rated current, frequency and wave shape.

Vehicular integration of wireless power transfer systems and hardware interoperability case studies

Several wireless charging methods are under development or available as an aftermarket option in the light-duty automotive market. However, there are not a sufficient number of studies detailing the vehicle integration methods, particularly a complete vehicle integration with higher power levels. This paper presents the design, development, implementation, and vehicle integration of wireless power transfer (WPT)-based electric vehicle (EV) charging systems for various test vehicles. Before having the standards effective, it is expected that WPT technology first will be integrated as an aftermarket retrofitting approach. Inclusion of this technology on production vehicles is contingent upon the release of the international standards. The power stages of the system are introduced with the design specifications and control systems including the active front-end rectifier with power factor correction, high frequency power inverter, high frequency isolation transformer, coupling coils, vehicle side full-bridge rectifier and filter, and the vehicle battery. The operating principles of the control, and communications, systems are presented. Aftermarket conversion approaches including the WPT on-board charger (OBC) integration, WPT CHAdeMO integration, and WPT direct battery connection scenarios are described. The experiments are carried out using the integrated vehicles and the results obtained to demonstrate the system performance including the stage-by-stage efficiencies.