Steven L Campbell

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.

Benchmarking EV and HEV power electronics and electric machines

This paper presents information from an ongoing benchmarking project being conducted at Oak Ridge National Laboratory (ORNL) and funded by the Department of Energy (DOE). Beginning with the 2004 Toyota Prius, ORNL has benchmarked components from many on-the-road EVs, HEVs, and PHEVs. Detailed design, packaging, and operational assessments are presented on power electronic converters (such as inverters, buck converters, and bi-directional boost converters), electric motors (such as the primary drive motor and generator), and other associated components. Packaging assessments reveal mass, volume, and material compositions, and empirical evaluations provide efficiency, performance, and operational data throughout the entire operation range of each component.

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.

Integrated charger with wireless charging and boost functions for PHEV and EV applications

Integrated charger topologies that have been researched so far with dc-dc converters and the charging functionality have no isolation in the system. Isolation is an important feature that is required for user interface systems that have grid connections and therefore is a major limitation that needs to be addressed along with the integrated functionality. The topology proposed in this paper is a unique and a first of its kind topology that integrates a wireless charging system and the boost converter for the traction drive system. The new topology is also compared with an on-board charger system from a commercial electric vehicle (EV). The ac-dc efficiency of the proposed system is 85.1% and the specific power and power density of the onboard components is ~455 W/kg and ~320 W/l.

Isolated wired and wireless battery charger with integrated boost converter for PEV applications

Integrated charger topologies that have been researched so far are with the dc-dc converters and the charging functionality usually have no isolation in the system. Isolation is an important feature that is required for user interface systems that have grid connections and therefore is a major limitation that needs to be addressed along with the integrated functionality. This study features a unique way of combining the wired and wireless charging functionalities with vehicle side boost converter integration and maintaining the isolation to provide the best solution to the plug-in electric vehicle (PEV) users. The new performance of the proposed architecture is presented for wired and wireless charging options at different power levels.