Plug-In Electric Vehicles: Motivation, Architecture, and Impact

1. Plug-In Electric Vehicles: Motivation, Architecture, and Impact Shawn Midlam-Mohler, PhD, PE Assistant Professor of Practice Ohio State University Department of Mechanical Engineering and Ohio State University Center for Automotive Research

2. Introduction • Motivation for PEVs • PEV Technology • Well-to-Wheels Impact • Grid Impact

3. World Oil Supply “Long-Term World Oil Supply Scenarios - The Future Is Neither as Bleak or Rosy as Some Assert”, John H. Wood, Gary R. Long, David F. Morehouse, DOE/EIA Report, August, 2004.

4. Importance of Petroleum in the U.S. ~70% for transportation NGPL = Natural Gas Plant Liquids “State and U.S. Historical Data”, US Report DOE/EIA, January 2007

5. World Oil Supply Estimates “Long-Term World Oil Supply Scenarios - The Future Is Neither as Bleak or Rosy as Some Assert”, John H. Wood, Gary R. Long, David F. Morehouse, DOE/EIA Report, August, 2004.

6. Energy Use and Per Capita GDP

7. EV and PHEV Technology

8. Fueling the Future:An Early Perspective "The use of vegetable oils for engine fuels may seem insignificant today, but such oils may become in the course of time as important as the petroleum and coal tar products of the present time.“ - Rudolph Diesel, 1912 "The fuel of the future is going to come from fruit like that sumac out by the road, or from apples, weeds, sawdust - almost anything. There is fuel in every bit of vegetable matter that can be fermented. There's enough alcohol in one year's yield of an acre of potatoes to drive the machinery necessary to cultivate the fields for a hundred years.“ - Henry Ford, 1925

9. Electrified Vehicles: Then and Now Hybrid Electric Vehicles 1917 Woods Dual Power 2010 Chevy Volt Electric Vehicles 1914 Detroit Electric Model 47 2010 Nissan Leaf

10. Plugging-in .. how many PEVs?? Courtesy of California Air Resources Board • Based on the historical rate of hybrid electric vehicle (HEV) growth as a benchmark for the first 10 years, and realistic technology sales growth projections by 2020 based on known technical and infrastructure challenges

11. Where does the Energy Go? In urban driving, how much fuel energy is actually used propel a conventional vehicle? a) 6% b) 13% c) 23% d) 31% Overcoming aerodynamic drag ?% ?% ?% Overcoming tire rolling resistance ?% ?% ?% Dissipation of kinetic energy ?% ?% ?%

12. Where does the Energy Go? In urban driving, how much fuel energy is actually used propel a conventional vehicle? a) 6% b) 13% c) 23% d) 31% Overcoming aerodynamic drag Overcoming tire rolling resistance ?% ?% Dissipation of kinetic energy

13. Conventional Vehicle • Efficiency improvements hard fought – usually focusing on the engine, driveline, and accessories • Advanced engine technology (Diesel, variable valve timing, etc.) are all part of the solution • Reduced vehicle size is one of the most reliable means of reducing fuel economy Engine Transmission Fuel Tank

14. Mild Hybrid • A Belted Starter Alternator (BSA) is a small electric motor coupled to the engine in place of the alternator • The motor allows the engine to be restarted rapidly, which reduces idle time (i.e. standby losses) • The small battery pack for the BSA allows electrification of accessories BSA Engine Transmission Battery Pack Fuel Tank

15. Full Hybrid • A hybrid vehicle contains at least one large electric motor, usually two in today’s production vehicles • The motors allow engine stop-start and downsizing of the engine for more efficient operation • More aggressive regenerative braking is also possible as are electric accessories EM Engine Transmission EM Battery Pack Fuel Tank

16. Hybrid Fuel Economy Comparison Five cars with conventional and hybrid models: Honda Civic Nissan Altima Ford Escape Toyota Highlander Chevy Tahoe City Fuel Economy: ~50% better for HEV Highway Fuel Economy: ~10% better for HEV

17. Electric Vehicle • Vehicle is independent of petroleum and zero emissions • Typically reduced range (<100 miles) and long recharge times (several hours) • Well-to-Wheel analysis is critical Electric Motor Transmission Battery Pack

18. Sample EV Window Sticker

19. Plug-In Hybrid Electric Vehicles • Cross between HEV and Electric Vehicle • In vehicles like the Chevy Volt, the vehicle can go 30 miles using only electricity • After which, it operates like a conventional HEV • For many drivers, functions as an EV during daily commute EM Engine Transmission EM Battery Pack Fuel Tank

20. Sample PHEV Window Sticker

21. Technology Summary • Technologies Discussed: • Mild Hybrids, Full Hybrids, Electric Vehicles, Plug-In Hybrids • PHEVs a good compromise between EV and HEV • Other Technologies can come to bear on the issue: • Fuel Cells • Alternative Fuels • Alternative Combustion Modes • Waste Heat Recovery • Many others • Current designs are largely no-compromise designs

22. Well-to-Wheels Analysis

23. Types of Vehicles • Charge Sustaining Electric Drive Vehicles: • Today’s HEVs • No ability to connect to grid • All energy comes from on-board chemical fuel • Charge Depleting Electric Drive Vehicles: • PHEVs and EVs • Require or expected to be connected to grid • For PHEVs, energy is mix between on-board chemical fuel and electricity • The latter category requires a more in-depth approach for evaluating the impact

24. Timing of Charging Matters for PEVs

25. Location of Charging Matters for PEVs

26. Usage Patterns Matter for PEVs

27. Well-to-Wheel Analysis • For advanced technology vehicles and alternative fuels, a well-to-wheel analysis is vital • There are no emissions from an electric vehicle directly – but where does the fuel come from? • For biomass based fuels, there is considerable debate on the true life-cycle cost of the fuels Regulated Emissions, Greenhouse Gas Emissions, High Energy Conversion Losses (Chemical->Mechanical->Electrical) Zero Emissions, High Efficiency

28. Well-to-Wheel Petroleum Usage

29. Well-to-Wheel GHG Emissions

30. Well-to-Wheel NOx Emissions

31. Well-to-Wheel SOx Emissions

32. Well-to-Wheels Conclusions • Charge depleting electric drive vehicles can offer major gains in petroleum usage and greenhouse gas emissions • Certain regulated emissions can increase from conventional vehicles • Generation mix, time of charging events, and vehicle driving patterns all impact environmental impact • Charge sustaining electric drive vehicles (i.e. today’s conventional HEVs) offer more modest improvements in petroleum and GHG with no increase in regulated emissions

33. What IS OSU Doing in this AREA?

34. OSU PEV Activities • Education at undergraduate and graduate level (GATE Program) • Privately funded research in the area of batteries, PEV control, advanced vehicle lubricants, and much more • Consortium funded research in many areas through SMART@CAR Consortium • Student motorsports projects: • Electric Motorcycle • Buckeye Bullet 3 • EcoCAR 2

35. What is EcoCAR 2? • A three year student vehicle competition: • 15 top schools selected in competitive entry process • Engineering, business, and communications focus • Students focus on: • Improving efficiency • Reducing emissions • Reducing petroleum usage • Improving stock performance and consumer features • GM provides a 2013 Chevy Malibu at the start of Year 2

36. OSU EcoCAR 2 Vehicle Components A123 Systems Battery Pack 1.8L E85 Engine Parker-Hannifin Electric Machine and BorgWarner Single Speed Gearbox Parker-Hannifin Electric Machine and GM 6-Speed Automated Manual Transmission

37. OSU EcoCAR 2 Vehicle Modes Charge-Depleting Front

38. OSU EcoCAR 2 Vehicle Modes Charge-Sustaining Series Front

39. OSU EcoCAR 2 Vehicle Modes Charge-Sustaining Parallel Front

40. Year 1 Results Second Place Overall

41. Questions?